A non-ferrous metal ultrasonic-assisted vacuum die casting forming device and method

Abstract

This invention relates to the field of metal die casting technology, and more specifically, to an ultrasonic-assisted vacuum die casting apparatus and method for non-ferrous metals. The apparatus includes a forming mold, a casting system, a vacuum system, and a vibration demolding system. The forming mold has a cavity. The casting system is connected to the forming mold and is used to inject liquid metal into the cavity. The vacuum system is connected to the forming mold and is used to evacuate the cavity. The vibration demolding system is connected to the forming mold and is used for ultrasonic vibration and demolding. Evacuating the cavity allows the molten metal to fill it more easily, reducing porosity and increasing density. The vibration demolding system vibrates the semi-solid metal material cooled to a certain point within the cavity, breaking up grains and venting air, thereby producing die-cast parts with clear interfaces, high density, and high strength and quality. The vibration also automatically cuts off the small gate point of the casting and solidified material.

Description

Technical Field

[0001] This invention relates to the field of metal die casting technology, and more specifically, to an ultrasonic-assisted vacuum die casting apparatus and method for non-ferrous metals. Background Technology

[0002] Die casting is a metal forming and manufacturing technology that involves rapidly injecting molten metal into a mold cavity. The high pressure allows the molten metal to quickly fill the cavity, ensuring contact between the metal and the mold, and enabling rapid cooling of the molten metal within the mold, thus achieving a casting with good surface quality. However, for thin-walled castings, the inconsistent temperature of the non-ferrous metal being processed within the mold cavity, especially in hypoeutectic aluminum and zinc alloys, can lead to the formation of coarse dendrite structures in the solid solution. This results in high strength but also high brittleness, making it difficult to guarantee the product's mechanical properties. Particularly for low-Si hypoeutectic aluminum alloys, their poor fluidity and the sequential precipitation of the aluminum matrix can cause the formation of large, attractive dendrite clusters, or large solid grains in the slurry that block fluid flow and filling within the thin-walled mold cavity, leading to product defects. Summary of the Invention

[0003] To overcome the problem of poor mechanical properties in non-ferrous metal die casting in the prior art, the first aspect of the present invention provides an ultrasonic-assisted vacuum die casting device for non-ferrous metals.

[0004] A second aspect of the present invention provides a method for ultrasonic-assisted vacuum die casting of non-ferrous metals.

[0005] To solve the above-mentioned technical problems, the technical solution adopted by the present invention is: an ultrasonic-assisted vacuum die-casting molding device for non-ferrous metals, comprising: a molding mold, a casting system, a vacuum system, and a vibration demolding system; the molding mold forming a mold cavity; the casting system being connected to the molding mold and used to inject liquid metal into the mold cavity; the vacuum system being connected to the molding mold and used to evacuate the mold cavity; the vibration demolding system comprising an ultrasonic component and a driving component, the fixed end of the ultrasonic component being fixedly connected to the driving component, the output end of the ultrasonic component being connected to the molding mold, and the driving component being used to drive the ultrasonic component to move and drive the molding mold to open and close.

[0006] In the technical solution of this invention, the vacuum system is used to evacuate the mold cavity, which makes it easier for the molten metal to fill the mold cavity, reduces the porosity and increases the density. The casting system can inject molten metal into the mold cavity, and the vibration demolding system can vibrate the metal raw material that has cooled to a semi-solid state in the mold cavity, which can break the grains and vent the air, thereby producing die-cast parts with clear interfaces, high density and high strength and high quality. The vibration can also automatically cut off the small gate of the casting and solidified material.

[0007] Furthermore, the molding die includes a fixed mold and a moving mold, the fixed mold and the moving mold are joined together to form the mold cavity, the casting system is connected to the fixed mold and communicates with the mold cavity, the vacuum system is connected to the fixed mold and communicates with the mold cavity, and the vibration demolding system is connected to the moving mold.

[0008] In this design, the structural layout places the casting system and vacuum system on the fixed mold side, and the vibration demolding system on the moving mold side, achieving a reasonable partitioning of functional components. The casting system is connected to the fixed mold, facilitating the stable injection of molten metal into the mold cavity when the mold is closed. The vacuum system is also connected to the fixed mold, enabling stable evacuation of the mold cavity. The vibration demolding system is connected to the moving mold, which not only breaks up grains and vents air, but also applies ultrasonic vibration directly to the solidified part on the moving mold when the mold is opened, which helps to separate the part from the mold cavity and achieve demolding.

[0009] Furthermore, the casting system includes a hopper, a cylinder, a heating component, a pressurizing component, and a valve. The cylinder is fixedly connected to the fixed mold and communicates with the mold cavity. The hopper is connected to the cylinder. The valve is provided at the connection outlet between the hopper and the cylinder. The heating component is connected to the cylinder. The pressurizing component is movably connected to the cylinder.

[0010] In this solution, the casting system enables precise control of the molten metal injection process. The heating component heats the molten metal in the barrel to maintain a set temperature before injection, preventing the molten metal from cooling too early and ensuring its fluidity. The pressurizing component moves inside the barrel to apply pressure to the molten metal, injecting it into the mold cavity at high speed, ensuring that the molten metal fills the mold cavity in good condition and reducing casting defects.

[0011] Furthermore, the heating element is a resistance wire or heating coil arranged around the barrel.

[0012] In this design, the surrounding heating structure enables uniform heating of the barrel. The resistance wire or heating coil is arranged around the barrel, increasing the contact area with the barrel and allowing heat to be evenly transferred to the molten metal inside the barrel. This avoids local overheating or overcooling and ensures the stability of the molten metal temperature. At the same time, this structure is simple and compact, easy to install, and has high heating efficiency, which helps maintain good fluidity of the molten metal during the injection process.

[0013] Furthermore, the output end of the ultrasound component is fixedly connected to the moving model.

[0014] In this design, the drive component provides the moving power for the ultrasonic component, driving the moving mold connected to its output end to perform mold opening or ejection actions. When the ultrasonic component is working, its output end directly transmits ultrasonic vibrations to the moving mold, allowing the vibrations to act more directly on the workpiece within the mold cavity and reducing energy loss during transmission. This connection method ensures the completion of the demolding action while effectively utilizing the role of ultrasonic vibration in breaking up grains and promoting venting, thereby improving demolding efficiency and workpiece quality.

[0015] Furthermore, the ultrasonic component includes an amplitude transformer, an ultrasonic tool head, a transducer, and an ultrasonic generator. One end of the amplitude transformer is fixedly connected to the drive component, and the other end of the amplitude transformer is connected to the ultrasonic tool head. The transducer is mounted on the amplitude transformer, and the ultrasonic generator is electrically connected to the transducer. A first mounting hole is provided through the moving mold, and the amplitude transformer passes through the first mounting hole and is fixedly connected to the moving mold. The end of the ultrasonic tool head away from the amplitude transformer is sealed at the end of the first mounting hole near the inner wall of the mold cavity.

[0016] In this solution, the ultrasonic assembly, through the cooperation of its various components, converts electrical energy into mechanical vibration and transmits it to the molten metal inside the mold cavity. The ultrasonic generator produces a high-frequency electrical signal, which drives the transducer to convert it into mechanical vibration of the same frequency. The amplitude transformer amplifies the amplitude of the mechanical vibration and transmits it to the ultrasonic tool head. The ultrasonic tool head acts directly on the inner wall of the mounting hole of the moving mold, efficiently introducing the vibration energy into the mold cavity. At the same time, the ultrasonic tool head is sealed at one end of the inner side wall of the mounting hole, which can prevent the molten metal from entering the mounting hole during injection and avoid the amplitude transformer or ultrasonic tool head from being jammed due to metal solidification, thus ensuring the reliability and stability of the vibration demolding system.

[0017] Furthermore, the ultrasonic component also includes an ultrasonic pull rod, a second mounting hole is provided through the moving mold, one end of the ultrasonic pull rod is fixedly connected to the drive component, the other end of the ultrasonic pull rod passes through the second mounting hole and is fixedly connected to the moving mold, and the end of the ultrasonic pull rod connected to the moving mold extends into the mold cavity and has a hook-shaped part.

[0018] In this design, one end of the pull rod is connected to the drive assembly, and the other end passes through the moving mold and extends into the mold cavity. Its hook-shaped portion embeds into the workpiece after the molten metal solidifies. When the drive assembly moves the pull rod, the hook-shaped portion applies a pulling force to the workpiece, assisting in its removal from the mold cavity. As part of the ultrasonic component, the pull rod can directly transmit ultrasonic vibrations to the hook-shaped portion extending into the mold cavity, thereby acting on the molten metal during solidification. This helps to break up grains and promote gas expulsion, improving the internal quality of the workpiece. Furthermore, the hook-shaped portion also plays a positioning role during mold closing and molten metal injection, preventing workpiece displacement.

[0019] Furthermore, the driving assembly includes a first fixed plate, a second fixed plate, and a push rod. The first fixed plate and the second fixed plate are fixedly connected. The first fixed plate has a pushing hole. The push rod passes through the pushing hole and is fixedly connected to the second fixed plate. The second fixed plate has multiple top rod holes. One end of the amplitude transformer and the ultrasonic pulling rod are both fixedly connected to the top rod holes.

[0020] In this design, the push rod passes through the push hole of the first fixed plate and is fixedly connected to the second fixed plate, enabling stable transmission of external power to the second fixed plate. Multiple push rod holes are provided on the second fixed plate for fixing the amplitude transformer and the ultrasonic pulling rod, allowing one drive assembly to simultaneously drive multiple vibration elements to move synchronously, ensuring the consistency and synchronicity of the demolding action.

[0021] Furthermore, the vacuum system includes a vacuum pump and a vacuum channel, the vacuum channel passing through the fixed mold and communicating with the mold cavity, and the output end of the vacuum pump being connected to the vacuum channel.

[0022] In this scheme, when the vacuum pump is working, the gas in the mold cavity is extracted through the vacuum channel, and a certain degree of vacuum is formed in the mold cavity before the molten metal is injected. This helps to reduce the resistance when the molten metal flows, making it easier to fill all corners of the mold cavity. At the same time, it reduces the phenomenon of molten metal entrapment, reduces the porosity inside the die casting, and improves the density of the part.

[0023] A method for ultrasonic-assisted vacuum die casting of non-ferrous metals, implemented using the aforementioned apparatus, includes: mixing raw materials in a specified ratio and heating them to form a liquid raw material; creating a negative pressure in the mold cavity using a vacuum system; injecting the liquid raw material into the mold cavity; when the liquid raw material in the mold cavity cools to a semi-solid temperature range; vibrating the raw material in the mold cavity using a vibration demolding system; stopping the vibration when the liquid raw material in the mold cavity continues to cool to below the semi-solid temperature range; and demolding the product after complete cooling.

[0024] Compared with the prior art, the beneficial effects of the present invention are: I. The non-ferrous metal ultrasonic-assisted vacuum die casting molding device of the present invention uses a vacuum system to evacuate the mold cavity, which makes it easier for the molten metal to fill the mold cavity, reduces porosity, and increases density. The casting system can inject molten metal into the mold cavity, and the vibration demolding system can vibrate the metal raw material cooled to a semi-solid state in the mold cavity, which can break the grains and vent the air, thereby producing die-cast parts with clear interfaces, high density, and high strength and high quality. The vibration can also automatically cut off the small gate of the casting and solidified material.

[0025] II. The non-ferrous metal ultrasonic-assisted vacuum die casting method of the present invention, when used in conjunction with the device of the present invention, vibrates in the semi-solid temperature range of the molten metal, which can refine the alloy grains in the part and produce die-cast parts with clear interfaces, high density and high strength and high quality. Attached Figure Description

[0026] Figure 1 This is a cross-sectional view of the overall structure of the non-ferrous metal ultrasonic-assisted vacuum die-casting molding device of the present invention; Figure 2 This is a schematic diagram of the first state of the ultrasonic-assisted vacuum die-casting molding device for non-ferrous metals; Figure 3 This is a schematic diagram of the second state of the ultrasonic-assisted vacuum die-casting molding device for non-ferrous metals; Figure 4 This is a schematic diagram of the third state of the ultrasonic-assisted vacuum die-casting molding device for non-ferrous metals; Figure 5 This is a schematic diagram of the fourth state of the ultrasonic-assisted vacuum die-casting molding device for non-ferrous metals; Figure 6 This is a schematic diagram of the fifth state of the ultrasonic-assisted vacuum die-casting molding device for non-ferrous metals; Figure 7 This is a schematic diagram of the sixth state of the ultrasonic-assisted vacuum die-casting molding device for non-ferrous metals; Figure 8 It is a picture of a standard tensile specimen; Figure 9 This is a schematic diagram of the dimensions of a standard tensile specimen; Figure 10 It is an Al-Si binary phase diagram; Figure 11 It is a binary phase diagram of the Zn-Al system; Figure 12 The microstructure morphology of the Al-6Si hypoeutectic alloy die casting prepared in Example 1 is shown. Figure 13 Microstructure morphology of the Al-6Si hypoeutectic alloy die casting prepared in Comparative Example 1; Figure 14 Microstructure morphology of the Al-2Si hypoeutectic alloy die casting prepared in Example 2; Figure 15 Microstructure morphology of the Al-2Si hypoeutectic alloy die casting prepared in Comparative Example 2; Figure 16 Microstructure morphology of the 6201 alloy die casting prepared in Example 3; Figure 17 Microstructure morphology of the 6201 alloy die casting prepared in Comparative Example 3; Figure 18Microstructure morphology of the Al-20Si alloy die casting prepared in Example 4; Figure 19 Microstructure morphology of the Al-20Si alloy die casting prepared in Comparative Example 4; Figure 20 Microstructure morphology of the Zn-4Al alloy die casting prepared in Example 5; Figure 21 Microstructure morphology of the Zn-4Al alloy die casting prepared in Comparative Example 5; Figure 22 Microstructure morphology of the Zn-6Al alloy die casting prepared in Example 6; Figure 23 Microstructure morphology of the Zn-6Al alloy die casting prepared in Comparative Example 6; Figure 24 Microstructure morphology of the Zn-8Al alloy die casting prepared in Example 7; Figure 25 Microstructure morphology of the Zn-8Al alloy die casting prepared in Comparative Example 7; Figure 26 Microstructure morphology of the Zn-10Al alloy die casting prepared in Example 8; Figure 27 Microstructure morphology of the Zn-10Al alloy die casting prepared in Comparative Example 8.

[0027] In the attached diagram: 1. Molding mold; 11. Mold cavity; 12. Fixed mold; 13. Moving mold; 131. First mounting hole; 132. Second mounting hole; 14. Thermocouple; 2. Casting system; 21. Hopper; 22. Material cylinder; 23. Heating component; 24. Pressurizing component; 25. Valve; 3. Vacuum system; 31. Vacuum pump; 32. Vacuum channel; 4. Vibration demolding system; 41. Ultrasonic component; 411. Amplitude rod; 412. Ultrasonic tool head; 413. Transducer; 414. Ultrasonic generator; 415. Ultrasonic pull rod; 4151. Hook-shaped part; 42. Drive component; 421. First fixing plate; 4211. Push hole; 422. Second fixing plate; 4221. Ejector hole; 423. Push rod. Detailed Implementation

[0028] The accompanying drawings are for illustrative purposes only and should not be construed as limiting this patent. To better illustrate this embodiment, some components in the drawings may be omitted, enlarged, or reduced, and do not represent the actual dimensions of the product. It is understandable to those skilled in the art that some well-known structures and their descriptions may be omitted in the drawings. The positional relationships described in the drawings are for illustrative purposes only and should not be construed as limiting this patent.

[0029] In the accompanying drawings of the embodiments of the present invention, the same or similar reference numerals correspond to the same or similar components. In the description of the present invention, it should be understood that if terms such as "upper," "lower," "left," "right," "long," and "short" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the drawings, 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, the terms used to describe positional relationships in the drawings are only for illustrative purposes and should not be construed as limiting the present patent. For those skilled in the art, the specific meaning of the above terms can be understood according to the specific circumstances.

[0030] The technical solution of the present invention will be further described in detail below through specific embodiments and with reference to the accompanying drawings: Example 1 refer to Figures 1 to 7 This embodiment discloses an ultrasonic-assisted vacuum die-casting molding device for non-ferrous metals, including a molding mold 1, a casting system 2, a vacuum system 3, and a vibration demolding system 4. The molding mold 1 forms a mold cavity 11. The casting system 2 is connected to the molding mold 1 and is used to inject liquid metal into the mold cavity 11. The vacuum system 3 is connected to the molding mold 1 and is used to evacuate the mold cavity 11. The vibration demolding system 4 includes an ultrasonic component 41 and a driving component 42. The fixed end of the ultrasonic component 41 is fixedly connected to the driving component 42, and the output end of the ultrasonic component 41 is connected to the molding mold 1. The driving component 42 is used to drive the ultrasonic component 41 to move and to drive the molding mold 1 to open and close.

[0031] The non-ferrous metal ultrasonic-assisted vacuum die casting device of this embodiment uses a vacuum system 3 to evacuate the mold cavity 11, which makes it easier for the molten metal to fill the mold cavity 11, reduces the porosity and increases the density. The casting system 2 can inject molten metal into the mold cavity 11. The vibration demolding system 4 vibrates the metal raw material in the mold cavity 11 that has cooled to a semi-solid state, which can break up the grains and vent the air, thereby producing die-cast parts with clear interfaces, high density and high strength and high quality. The vibration can also automatically cut off the small gate of the casting and solidified material.

[0032] refer to Figure 1 The molding die 1 includes a fixed die 12 and a movable die 13, which are closed to form a mold cavity 11. A casting system 2 is connected to the fixed die 12 and communicates with the mold cavity 11. A vacuum system 3 is connected to the fixed die 12 and communicates with the mold cavity 11. A vibration demolding system 4 is connected to the movable die 13. More specifically, refer to... Figure 1After the fixed mold 12 and the moving mold 13 are closed, a mold cavity 11 and a runner are formed between them. The runner connects the casting system 2 to the mold cavity 11, and a small connection port is formed at the connection between the runner and the mold cavity 11, allowing the molten metal to be injected into the mold cavity 11 under high pressure. A thermocouple 14 is connected to the fixed mold 12 to detect the temperature inside the mold cavity 11.

[0033] In this embodiment, the structural layout places the casting system 2 and the vacuum system 3 on the fixed mold 12 side and the vibration demolding system 4 on the moving mold 13 side, achieving reasonable partitioning of functional components. The casting system 2 is connected to the fixed mold 12, which facilitates the stable injection of molten metal into the mold cavity 11 when the mold is closed. The vacuum system 3 is also connected to the fixed mold 12, which can stably evacuate the mold cavity 11. The vibration demolding system 4 is connected to the moving mold 13, which can not only break up grains and vent air, but also directly apply ultrasonic vibration to the solidified part on the moving mold 13 when the mold is opened, which helps to separate the part from the mold cavity and achieve demolding.

[0034] refer to Figure 1 The casting system 2 includes a hopper 21, a cylinder 22, a heating component 23, a pressurizing component 24, and a valve 25. The cylinder 22 is fixedly connected to the fixed mold 12 and communicates with the mold cavity 11. The hopper 21 is connected to the cylinder 22. A valve 25 is provided at the connection outlet between the hopper 21 and the cylinder 22. The heating component 23 is connected to the cylinder 22. The pressurizing component 24 is movably connected in the cylinder 22.

[0035] In this embodiment, the casting system 2 can precisely control the injection process of molten metal. The heating component 23 heats the molten metal in the barrel 22 to maintain the set temperature before injection, preventing the molten metal from cooling too early and ensuring its fluidity. The pressurizing component 24 moves in the barrel 22 to apply pressure to the molten metal and inject it into the mold cavity 11 at high speed, ensuring that the molten metal fills the mold cavity 11 in a good state and reducing casting defects.

[0036] refer to Figure 1 The heating element 23 is a resistance wire or heating coil arranged around the barrel 22. In this embodiment, the surrounding heating structure can achieve uniform heating of the barrel 22. The resistance wire or heating coil is arranged around the barrel 22, which increases the contact area with the barrel 22, so that heat can be evenly transferred to the molten metal in the barrel 22, avoiding local overheating or overcooling, and ensuring the stability of the molten metal temperature. At the same time, this structure is simple and compact, easy to install, and has high heating efficiency, which helps to maintain good fluidity of the molten metal during the injection process.

[0037] refer to Figure 1 The output end of the ultrasonic component 41 is fixedly connected to the moving model 13.

[0038] In this embodiment, the drive component 42 provides the moving power for the ultrasonic component 41, driving the moving mold 13 connected to its output end to perform mold opening or ejection actions. When the ultrasonic component 41 is working, its output end directly transmits ultrasonic vibrations to the moving mold 13, allowing the vibrations to act more directly on the workpiece inside the mold cavity 11, reducing energy loss in the transmission path. This connection method not only ensures the completion of the demolding action but also effectively utilizes the role of ultrasonic vibration in breaking grains and promoting venting, thereby improving demolding efficiency and workpiece quality.

[0039] refer to Figure 1 The ultrasonic component 41 includes an amplitude transformer 411, an ultrasonic tool head 412, a transducer 413, and an ultrasonic generator 414. One end of the amplitude transformer 411 is fixedly connected to the drive component 42, and the other end of the amplitude transformer 411 is connected to the ultrasonic tool head 412. The amplitude transformer 411 is provided with a transducer 413, and the ultrasonic generator 414 is electrically connected to the transducer 413. A first mounting hole 131 is provided through the moving mold 13, and the amplitude transformer 411 passes through the first mounting hole 131 and is fixedly connected to the moving mold 13. The end of the ultrasonic tool head 412 away from the amplitude transformer 411 is sealed at the end of the first mounting hole 131 near the inner sidewall of the mold cavity 11.

[0040] In this embodiment, the ultrasonic component 41, through the cooperation of its various parts, converts electrical energy into mechanical vibration and transmits it to the molten metal in the mold cavity 11. The ultrasonic generator 414 generates a high-frequency electrical signal, which drives the transducer 413 to convert it into mechanical vibration of the same frequency. The amplitude transformer 411 amplifies the amplitude of the mechanical vibration and transmits it to the ultrasonic tool head 412. The ultrasonic tool head 412 acts directly on the inner wall of the mounting hole of the moving mold 13, efficiently introducing the vibration energy into the mold cavity 11. At the same time, the ultrasonic tool head 412 is sealed at one end of the inner side wall of the mounting hole, which can prevent the molten metal from entering the mounting hole during injection and avoid the amplitude transformer 411 or the ultrasonic tool head 412 from being stuck due to metal solidification, thus ensuring the reliability and stability of the vibration demolding system 4.

[0041] refer to Figure 1 The ultrasonic component 41 also includes an ultrasonic pull rod 415. A second mounting hole 132 is provided through the moving mold 13. One end of the ultrasonic pull rod 415 is fixedly connected to the drive component 42, and the other end of the ultrasonic pull rod 415 passes through the second mounting hole 132 and is fixedly connected to the moving mold 13. The end of the ultrasonic pull rod 415 connected to the moving mold 13 extends into the mold cavity 11 and has a hook-shaped part 4151.

[0042] In this embodiment, one end of the pull rod is connected to the drive assembly 42, and the other end passes through the moving mold 13 and extends into the mold cavity 11. Its hook-shaped portion 4151 is embedded in the part after the molten metal solidifies. When the drive assembly 42 moves the pull rod, the hook-shaped portion 4151 applies a pulling force to the part, assisting the part to be ejected from the mold cavity 11. As part of the ultrasonic component 41, the pull rod can directly transmit ultrasonic vibrations to the hook-shaped portion 4151 extending into the mold cavity 11, thereby acting on the molten metal during the solidification process, which helps to break up grains and promote gas discharge, improving the internal quality of the part. In addition, the hook-shaped portion 4151 can also play a positioning role during mold closing and liquid injection, preventing the part from shifting.

[0043] refer to Figure 1 The drive assembly 42 includes a first fixed plate 421, a second fixed plate 422, and a push rod 423. The first fixed plate 421 and the second fixed plate 422 are fixedly connected. The first fixed plate 421 has a push hole 4211. The push rod 423 passes through the push hole 4211 and is fixedly connected to the second fixed plate 422. The second fixed plate 422 has a plurality of push rod holes 4221. One end of the amplitude rod 411 and the ultrasonic pulling rod 415 are fixedly connected to the push rod holes 4221.

[0044] In this embodiment, the push rod 423 passes through the push hole 4211 of the first fixed plate 421 and is fixedly connected to the second fixed plate 422, which can stably transmit external power to the second fixed plate 422. The second fixed plate 422 has multiple push rod holes 4221 for fixing and connecting the amplitude transformer rod 411 and the ultrasonic pulling rod 415, so that one drive assembly 42 can drive multiple vibration elements to move synchronously at the same time, ensuring the consistency and synchronicity of the demolding action.

[0045] refer to Figure 1 The vacuum system 3 includes a vacuum pump 31 and a vacuum channel 32. The vacuum channel 32 passes through the fixed mold 12 and is connected to the mold cavity 11. The output end of the vacuum pump 31 is connected to the vacuum channel 32.

[0046] In this embodiment, when the vacuum pump 31 is working, it extracts the gas in the mold cavity 11 through the vacuum channel 32, so that a certain degree of vacuum is formed in the mold cavity 11 before the molten metal is injected. This helps to reduce the resistance when the molten metal flows, making it easier to fill all corners of the mold cavity 11. At the same time, it reduces the phenomenon of molten metal entrapment, reduces the porosity inside the die casting, and improves the compactness of the part.

[0047] Based on the non-ferrous metal ultrasonic-assisted vacuum die casting apparatus disclosed in this embodiment, a non-ferrous metal ultrasonic-assisted vacuum die casting method is disclosed, including: mixing raw materials in proportion and heating to form liquid raw materials; forming negative pressure in mold cavity 11 through vacuum system 3; injecting liquid raw materials into mold cavity 11; when the liquid raw materials in mold cavity 11 cool to the semi-solid temperature range; vibrating the raw materials in mold cavity 11 through vibration demolding system 4; when the liquid raw materials in mold cavity 11 continue to cool to below the semi-solid temperature range; stopping vibration; and demolding to obtain the product after complete cooling.

[0048] refer to Figures 2 to 7 This paper describes the various stages of the production process of an ultrasonic-assisted vacuum die-casting molding device for non-ferrous metals, using illustrations. (Reference) Figure 2 The fixed mold 12 and the moving mold 13 close, and the valve 25 opens, quantitatively adding molten metal from the hopper 21 into the barrel 22. (Reference) Figure 3 Valve 25 is closed, and molten metal is forced into mold cavity 11 via pressurizing component 24, with ultrasonic vibration applied within the semi-solid temperature range. (Reference) Figure 4 After cooling, open the mold. (Reference) Figure 5 The product will be launched separately. (Reference) Figure 6 The moving mold 13 and the fixed mold 12 are then reassembled. (Reference) Figure 7 The pressurizing component 24 is returned for the next production run.

[0049] In conjunction with the above apparatus and method, the casting preparation process in this embodiment will be illustrated more specifically by example: A standard tensile specimen of Al-6Si hypoeutectic alloy was prepared using the apparatus and method of this embodiment. The shape and dimensions of the specimen are as follows: Figure 8 and Figure 9 As shown. The specific preparation steps are as follows: (1) Mix Al-20Si master alloy and high-purity aluminum (99.99%) raw materials in a mass ratio of 3:7, heat to 780℃ to melt, stir and keep warm for 30 minutes, remove slag and pour into hopper.

[0050] (2) Open the valve to inject the molten metal into the barrel in a measured amount, control the temperature at 680°C, and keep the molten metal in a fully liquid state.

[0051] (3) Apply release agent to the inner wall of the mold cavity where the fixed mold and the moving mold are located, close the fixed mold and the moving mold and apply clamping force.

[0052] (4) Turn on the vacuum pump to extract the air from the mold cavity and create a negative pressure in the mold cavity.

[0053] (5) Start the pressurizing component to apply pressure to the molten metal in the barrel, so that the molten metal is injected at high speed through the flow channel and fills the mold cavity.

[0054] (6) When the temperature measured by the thermocouple is 630℃, start the ultrasonic generator to apply ultrasonic vibration to the metal slurry in the mold cavity. The ultrasonic vibration frequency is 20kHz and the power is 200W. Stop the ultrasonic vibration when the temperature cools down to 580℃. The selection of the ultrasonic vibration temperature is based on... Figure 10 The Al-Si binary phase diagram shows that Al-6Si is a hypoeutectic alloy with a semi-solid temperature range of 577~630℃.

[0055] (7) After cooling to room temperature, the moving mold retracts and separates from the fixed mold, and the head of the ultrasonic pull rod hooks the solidified material and product in the flow channel and is carried away from the fixed mold.

[0056] (8) The ultrasonic ejector rod pushes the workpiece out under the action of the push rod. The ultrasonic generator is turned on, and the workpiece and the solidified material are automatically separated. The above steps can be repeated for continuous production.

[0057] Example 2 This embodiment prepares a standard tensile specimen of an Al-2Si hypoeutectic alloy, with the same shape and dimensions as in Example 1. The specific preparation steps are as follows: (1) Mix Al-20Si master alloy and high-purity aluminum (99.99%) raw materials in a mass ratio of 1:9, heat to 760℃ to melt, stir and keep warm for 30 minutes, remove slag and pour into hopper.

[0058] (2) Open the valve to inject the molten metal into the barrel in a measured amount, control the temperature at 680°C, and keep the molten metal in a fully liquid state.

[0059] (3) Apply release agent to the inner wall of the mold cavity where the fixed mold and the moving mold are located, close the fixed mold and the moving mold and apply clamping force.

[0060] (4) Turn on the vacuum pump to extract the air from the mold cavity and create a negative pressure in the mold cavity.

[0061] (5) Start the pressurizing component to apply pressure to the molten metal in the barrel, so that the molten metal is injected at high speed through the flow channel and fills the mold cavity.

[0062] (6) When the temperature measured by the thermocouple is 645℃, start the ultrasonic generator to apply ultrasonic vibration to the metal slurry in the mold cavity. The ultrasonic vibration frequency is 20kHz and the power is 300W. Stop the ultrasonic vibration when the temperature cools down to 580℃. The basis for selecting the ultrasonic vibration temperature comes from... Figure 10 The Al-Si binary phase diagram shows that Al-6Si is a hypoeutectic alloy with a semi-solid temperature range of 577~645℃.

[0063] (7) After cooling to room temperature, the moving mold retracts and separates from the fixed mold, and the head of the ultrasonic pull rod hooks the solidified material and product in the flow channel and is carried away from the fixed mold.

[0064] (8) The ultrasonic ejector rod pushes the workpiece out under the action of the push rod. The ultrasonic generator is turned on, and the workpiece and the solidified material are automatically separated. The above steps can be repeated for continuous production.

[0065] Example 3 This embodiment prepares a standard tensile specimen of 6201 aluminum alloy, with the same shape and dimensions as in Example 1. The specific preparation steps are as follows: (1) Heat the 6201 aluminum alloy to 740℃ to melt it, stir and keep it warm for 30 minutes, then remove the slag and pour it into the hopper.

[0066] (2) Open the valve to inject the molten metal into the barrel in a measured amount, control the temperature at 680°C, and keep the molten metal in a fully liquid state.

[0067] (3) Apply release agent to the inner wall of the mold cavity where the fixed mold and the moving mold are located, close the fixed mold and the moving mold and apply clamping force.

[0068] (4) Turn on the vacuum pump to extract the air from the mold cavity and create a negative pressure in the mold cavity.

[0069] (5) Start the pressurizing component to apply pressure to the molten metal in the barrel, so that the molten metal is injected at high speed through the flow channel and fills the mold cavity.

[0070] (6) When the temperature measured by the thermocouple is 650℃, start the ultrasonic generator to apply ultrasonic vibration to the metal slurry in the mold cavity. The ultrasonic vibration frequency is 20kHz and the power is 400W. Stop the ultrasonic vibration when the temperature cools down to 580℃. The selection of the ultrasonic vibration temperature is based on... Figure 10 The Al-Si binary phase diagram shows that 6201 contains 0.5%~0.9% Si and 0.5%~0.9% Mg, and has a semi-solid temperature range of 577~650℃.

[0071] (7) After cooling to room temperature, the moving mold retracts and separates from the fixed mold, and the head of the ultrasonic pull rod hooks the solidified material and product in the flow channel and is carried away from the fixed mold.

[0072] (8) The ultrasonic ejector rod pushes the workpiece out under the action of the push rod. The ultrasonic generator is turned on, and the workpiece and the solidified material are automatically separated. The above steps can be repeated for continuous production.

[0073] Example 4 This embodiment prepares a standard tensile specimen of Al-20Si aluminum alloy, with the same shape and dimensions as in Example 1. The specific preparation steps are as follows: (1) Heat the Al-20Si aluminum alloy to 750℃ to melt it, stir and keep it warm for 30 minutes, then remove the slag and pour it into the hopper.

[0074] (2) Open the valve to inject the molten metal into the barrel in a measured amount, control the temperature at 700℃, and keep the molten metal in a fully liquid state.

[0075] (3) Apply release agent to the inner wall of the mold cavity where the fixed mold and the moving mold are located, close the fixed mold and the moving mold and apply clamping force.

[0076] (4) Turn on the vacuum pump to extract the air from the mold cavity and create a negative pressure in the mold cavity.

[0077] (5) Start the pressurizing component to apply pressure to the molten metal in the barrel, so that the molten metal is injected at high speed through the flow channel and fills the mold cavity.

[0078] (6) When the temperature measured by the thermocouple is 650℃, start the ultrasonic generator to apply ultrasonic vibration to the metal slurry in the mold cavity. The ultrasonic vibration frequency is 20kHz and the power is 500W. Stop the ultrasonic vibration when the temperature cools down to 580℃. The basis for selecting the ultrasonic vibration temperature comes from... Figure 10 The Al-Si binary phase diagram shows that Al-20Si is a hypereutectic alloy with a semi-solid temperature range of 580~650℃. Ultrasonic cavitation within this range can effectively fragment the dendritic aluminum phase and modify the Si phase.

[0079] (7) After cooling to room temperature, the moving mold retracts and separates from the fixed mold, and the head of the ultrasonic pull rod hooks the solidified material and product in the flow channel and is carried away from the fixed mold.

[0080] (8) The ultrasonic ejector rod pushes the workpiece out under the action of the push rod. The ultrasonic generator is turned on, and the workpiece and the solidified material are automatically separated. The above steps can be repeated for continuous production.

[0081] Example 5 This embodiment prepares a standard tensile specimen of Zn-4Al zinc alloy, with the same shape and dimensions as in Example 1. The specific preparation steps are as follows: (1) Heat the Zn-4Al zinc alloy to 500℃ to melt it, stir and keep it warm for 30 minutes, then remove the slag and pour it into the hopper.

[0082] (2) Open the valve to inject the molten metal into the barrel in a measured amount, control the temperature at 500℃, and keep the molten metal in a fully liquid state.

[0083] (3) Apply release agent to the inner wall of the mold cavity where the fixed mold and the moving mold are located, close the fixed mold and the moving mold and apply clamping force.

[0084] (4) Turn on the vacuum pump to extract the air from the mold cavity and create a negative pressure in the mold cavity.

[0085] (5) Start the pressurizing component to apply pressure to the molten metal in the barrel, so that the molten metal is injected at high speed through the flow channel and fills the mold cavity.

[0086] (6) When the temperature measured by the thermocouple is 400℃, start the ultrasonic generator to apply ultrasonic vibration to the metal slurry in the mold cavity. The ultrasonic vibration frequency is 20kHz and the power is 550W. Stop the ultrasonic vibration when the temperature cools down to 380℃. The basis for selecting the ultrasonic vibration temperature comes from... Figure 11 The Zn-Al binary phase diagram shows a semi-solid temperature range of 380~400℃. Ultrasonic cavitation within this range can effectively fragment the dendritic αAl phase.

[0087] (7) After cooling to room temperature, the moving mold retracts and separates from the fixed mold, and the head of the ultrasonic pull rod hooks the solidified material and product in the flow channel and is carried away from the fixed mold.

[0088] (8) The ultrasonic ejector rod pushes the workpiece out under the action of the push rod. The ultrasonic generator is turned on, and the workpiece and the solidified material are automatically separated. The above steps can be repeated for continuous production.

[0089] Example 6 This embodiment prepares a standard tensile specimen of Zn-6Al zinc alloy, with the same shape and dimensions as in Example 1. The specific preparation steps are as follows: (1) Heat the Zn-6Al zinc alloy to 500℃ to melt it, stir and keep it warm for 30 minutes, then remove the slag and pour it into the hopper.

[0090] (2) Open the valve to inject the molten metal into the barrel in a measured amount, control the temperature at 500℃, and keep the molten metal in a fully liquid state.

[0091] (3) Apply release agent to the inner wall of the mold cavity where the fixed mold and the moving mold are located, close the fixed mold and the moving mold and apply clamping force.

[0092] (4) Turn on the vacuum pump to extract the air from the mold cavity and create a negative pressure in the mold cavity.

[0093] (5) Start the pressurizing component to apply pressure to the molten metal in the barrel, so that the molten metal is injected at high speed through the flow channel and fills the mold cavity.

[0094] (6) When the temperature measured by the thermocouple is 400℃, start the ultrasonic generator to apply ultrasonic vibration to the metal slurry in the mold cavity. The ultrasonic vibration frequency is 20kHz and the power is 600W. Stop the ultrasonic vibration when the temperature cools down to 380℃. The selection of the ultrasonic vibration temperature is based on... Figure 11 The Zn-Al binary phase diagram shows a semi-solid temperature range of 380~400℃. Ultrasonic cavitation within this range can effectively fragment the dendritic ηZn phase.

[0095] (7) After cooling to room temperature, the moving mold retracts and separates from the fixed mold, and the head of the ultrasonic pull rod hooks the solidified material and product in the flow channel and is carried away from the fixed mold.

[0096] (8) The ultrasonic ejector rod pushes the workpiece out under the action of the push rod. The ultrasonic generator is turned on, and the workpiece and the solidified material are automatically separated. The above steps can be repeated for continuous production.

[0097] Example 7 This embodiment prepares a standard tensile specimen of Zn-8Al zinc alloy, with the same shape and dimensions as in Example 1. The specific preparation steps are as follows: (1) Heat the Zn-8Al alloy to 500℃ to melt it, stir and keep it warm for 30 minutes, then remove the slag and pour it into the hopper.

[0098] (2) Open the valve to inject the molten metal into the barrel in a measured amount, control the temperature at 500℃, and keep the molten metal in a fully liquid state.

[0099] (3) Apply release agent to the inner wall of the mold cavity where the fixed mold and the moving mold are located, close the fixed mold and the moving mold and apply clamping force.

[0100] (4) Turn on the vacuum pump to extract the air from the mold cavity and create a negative pressure in the mold cavity.

[0101] (5) Start the pressurizing component to apply pressure to the molten metal in the barrel, so that the molten metal is injected at high speed through the flow channel and fills the mold cavity.

[0102] (6) When the temperature measured by the thermocouple is 400℃, start the ultrasonic generator to apply ultrasonic vibration to the metal slurry in the mold cavity. The ultrasonic vibration frequency is 20kHz and the power is 700W. Stop the ultrasonic vibration when the temperature cools down to 380℃. The basis for selecting the ultrasonic vibration temperature is based on Figure 11 The Zn-Al binary phase diagram shows a semi-solid temperature range of 380~400℃. Ultrasonic cavitation within this range can effectively fragment the dendritic ηZn phase.

[0103] (7) After cooling to room temperature, the moving mold retracts and separates from the fixed mold, and the head of the ultrasonic pull rod hooks the solidified material and product in the flow channel and is carried away from the fixed mold.

[0104] (8) The ultrasonic ejector rod pushes the workpiece out under the action of the push rod. The ultrasonic generator is turned on, and the workpiece and the solidified material are automatically separated. The above steps can be repeated for continuous production.

[0105] Example 8 This embodiment prepares a standard tensile specimen of Zn-10Al zinc alloy, with the same shape and dimensions as in Example 1. The specific preparation steps are as follows: (1) Heat the Zn-10Al zinc alloy to 500℃ to melt it, stir and keep it warm for 30 minutes, then remove the slag and pour it into the hopper.

[0106] (2) Open the valve to inject the molten metal into the barrel in a measured amount, control the temperature at 500℃, and keep the molten metal in a fully liquid state.

[0107] (3) Apply release agent to the inner wall of the mold cavity where the fixed mold and the moving mold are located, close the fixed mold and the moving mold and apply clamping force.

[0108] (4) Turn on the vacuum pump to extract the air from the mold cavity and create a negative pressure in the mold cavity.

[0109] (5) Start the pressurizing component to apply pressure to the molten metal in the barrel, so that the molten metal is injected at high speed through the flow channel and fills the mold cavity.

[0110] (6) When the temperature measured by the thermocouple is 400℃, start the ultrasonic generator to apply ultrasonic vibration to the metal slurry in the mold cavity. The ultrasonic vibration frequency is 20kHz and the power is 800W. Stop the ultrasonic vibration when the temperature cools down to 380℃. The selection of the ultrasonic vibration temperature is based on... Figure 11 The Zn-Al binary phase diagram shows a semi-solid temperature range of 380~400℃. Ultrasonic cavitation within this range can effectively fragment the dendritic ηZn phase.

[0111] (7) After cooling to room temperature, the moving mold retracts and separates from the fixed mold, and the head of the ultrasonic pull rod hooks the solidified material and product in the flow channel and is carried away from the fixed mold.

[0112] (8) The ultrasonic ejector rod pushes the workpiece out under the action of the push rod. The ultrasonic generator is turned on, and the workpiece and the solidified material are automatically separated. The above steps can be repeated for continuous production.

[0113] Comparative Example 1 Similar to Example 1, this comparative example prepares a standard tensile specimen of an Al-6Si hypoeutectic alloy. The difference is that ultrasonic vibration is not applied in this comparative example. The specific preparation steps are as follows: (1) Mix Al-20Si master alloy and high-purity aluminum (99.99%) raw materials in a mass ratio of 3:7, heat to 780℃ to melt, stir and keep warm for 30 minutes, remove slag and pour into hopper.

[0114] (2) Open the valve to inject the molten metal into the barrel in a measured amount, control the temperature at 680°C, and keep the molten metal in a fully liquid state.

[0115] (3) Apply release agent to the inner wall of the mold cavity where the fixed mold and the moving mold are located, close the fixed mold and the moving mold and apply clamping force.

[0116] (4) Turn on the vacuum pump to extract the air from the mold cavity and create a negative pressure in the mold cavity.

[0117] (5) Start the pressurizing component to apply pressure to the molten metal in the barrel, so that the molten metal is injected at high speed through the flow channel and fills the mold cavity.

[0118] (6) After cooling to room temperature, the moving mold retracts and separates from the fixed mold, and the head of the ultrasonic pull rod hooks the solidified material and product in the flow channel and is carried away from the fixed mold.

[0119] (7) The ultrasonic ejector rod pushes the part out under the action of the push rod. The part and the solidified material are then separated manually. The above steps can be repeated for continuous production.

[0120] Comparative Example 2 Similar to Example 2, this comparative example prepared a standard tensile specimen of an Al-2Si hypoeutectic alloy. The difference is that ultrasonic vibration was not applied in this comparative example. The specific preparation steps are as follows: (1) Mix Al-20Si master alloy and high-purity aluminum (99.99%) raw materials in a mass ratio of 1:9, heat to 760℃ to melt, stir and keep warm for 30 minutes, remove slag and pour into hopper.

[0121] (2) Open the valve to inject the molten metal into the barrel in a measured amount, control the temperature at 680°C, and keep the molten metal in a fully liquid state.

[0122] (3) Apply release agent to the inner wall of the mold cavity where the fixed mold and the moving mold are located, close the fixed mold and the moving mold and apply clamping force.

[0123] (4) Turn on the vacuum pump to extract the air from the mold cavity and create a negative pressure in the mold cavity.

[0124] (5) Start the pressurizing component to apply pressure to the molten metal in the barrel, so that the molten metal is injected at high speed through the flow channel and fills the mold cavity.

[0125] (6) After cooling to room temperature, the moving mold retracts and separates from the fixed mold, and the head of the ultrasonic pull rod hooks the solidified material and product in the flow channel and is carried away from the fixed mold.

[0126] (7) The ultrasonic ejector rod pushes the part out under the action of the push rod. The part and the solidified material are then separated manually. The above steps can be repeated for continuous production.

[0127] Comparative Example 3 This comparative example is similar to Example 2, preparing a standard tensile specimen of 6201 aluminum alloy. The difference is that ultrasonic vibration is not applied in this comparative example. The specific preparation steps are as follows: Compared to Example 2, ultrasonic vibration was not applied to the standard tensile specimen of 6201 aluminum alloy. The specific steps are as follows: (1) Heat the 6201 alloy to 740℃ to melt it, stir and keep it warm for 30 minutes, then remove the slag and pour it into the hopper.

[0128] (2) Open the valve to inject the molten metal into the barrel in a measured amount, control the temperature at 680°C, and keep the molten metal in a fully liquid state.

[0129] (3) Apply release agent to the inner wall of the mold cavity where the fixed mold and the moving mold are located, close the fixed mold and the moving mold and apply clamping force.

[0130] (4) Turn on the vacuum pump to extract the air from the mold cavity and create a negative pressure in the mold cavity.

[0131] (5) Start the pressurizing component to apply pressure to the molten metal in the barrel, so that the molten metal is injected at high speed through the flow channel and fills the mold cavity.

[0132] (6) After cooling to room temperature, the moving mold retracts and separates from the fixed mold, and the head of the ultrasonic pull rod hooks the solidified material and product in the flow channel and is carried away from the fixed mold.

[0133] (7) The ultrasonic ejector rod pushes the part out under the action of the push rod. The part and the solidified material are then separated manually. The above steps can be repeated for continuous production.

[0134] Comparative Example 4 This comparative example is similar to Example 2, preparing a standard tensile specimen of Al-20Si aluminum alloy. The difference is that ultrasonic vibration is not applied in this comparative example. The specific preparation steps are as follows: (1) Heat the Al-20Si aluminum alloy to 750℃ to melt it, stir and keep it warm for 30 minutes, then remove the slag and pour it into the hopper.

[0135] (2) Open the valve to inject the molten metal into the barrel in a measured amount, control the temperature at 700℃, and keep the molten metal in a fully liquid state.

[0136] (3) Apply release agent to the inner wall of the mold cavity where the fixed mold and the moving mold are located, close the fixed mold and the moving mold and apply clamping force.

[0137] (4) Turn on the vacuum pump to extract the air from the mold cavity and create a negative pressure in the mold cavity.

[0138] (5) Start the pressurizing component to apply pressure to the molten metal in the barrel, so that the molten metal is injected at high speed through the flow channel and fills the mold cavity.

[0139] (6) After cooling to room temperature, the moving mold retracts and separates from the fixed mold, and the head of the ultrasonic pull rod hooks the solidified material and product in the flow channel and is carried away from the fixed mold.

[0140] (7) The ultrasonic ejector rod pushes the part out under the action of the push rod. The part and the solidified material are then separated manually. The above steps can be repeated for continuous production.

[0141] Comparative Example 5 This comparative example is similar to Example 2, preparing a standard tensile specimen of Zn-4Al zinc alloy. The difference is that ultrasonic vibration is not applied in this comparative example. The specific preparation steps are as follows: (1) Heat the Zn-4Al alloy to 500℃ to melt it, stir and keep it warm for 30 minutes, then remove the slag and pour it into the hopper.

[0142] (2) Open the valve to inject the molten metal into the barrel in a measured amount, control the temperature at 500℃, and keep the molten metal in a fully liquid state.

[0143] (3) Apply release agent to the inner wall of the mold cavity where the fixed mold and the moving mold are located, close the fixed mold and the moving mold and apply clamping force.

[0144] (4) Turn on the vacuum pump to extract the air from the mold cavity and create a negative pressure in the mold cavity.

[0145] (5) Start the pressurizing component to apply pressure to the molten metal in the barrel, so that the molten metal is injected at high speed through the flow channel and fills the mold cavity.

[0146] (6) After cooling to room temperature, the moving mold retracts and separates from the fixed mold, and the head of the ultrasonic pull rod hooks the solidified material and product in the flow channel and is carried away from the fixed mold.

[0147] (7) The ultrasonic ejector rod pushes the part out under the action of the push rod. The part and the solidified material are then separated manually. The above steps can be repeated for continuous production.

[0148] Comparative Example 6 This comparative example is similar to Example 2, preparing a standard tensile specimen of Zn-6Al zinc alloy. The difference is that ultrasonic vibration is not applied in this comparative example. The specific preparation steps are as follows: (1) Heat the Zn-6Al zinc alloy to 500℃ to melt it, stir and keep it warm for 30 minutes, then remove the slag and pour it into the hopper.

[0149] (2) Open the valve to inject the molten metal into the barrel in a measured amount, control the temperature at 500℃, and keep the molten metal in a fully liquid state.

[0150] (3) Apply release agent to the inner wall of the mold cavity where the fixed mold and the moving mold are located, close the fixed mold and the moving mold and apply clamping force.

[0151] (4) Turn on the vacuum pump to extract the air from the mold cavity and create a negative pressure in the mold cavity.

[0152] (5) Start the pressurizing component to apply pressure to the molten metal in the barrel, so that the molten metal is injected at high speed through the flow channel and fills the mold cavity.

[0153] (6) After cooling to room temperature, the moving mold retracts and separates from the fixed mold, and the head of the ultrasonic pull rod hooks the solidified material and product in the flow channel and is carried away from the fixed mold.

[0154] (7) The ultrasonic ejector rod pushes the part out under the action of the push rod. The part and the solidified material are then separated manually. The above steps can be repeated for continuous production.

[0155] Comparative Example 7 This comparative example is similar to Example 2, preparing a standard tensile specimen of Zn-8Al zinc alloy. The difference is that ultrasonic vibration is not applied in this comparative example. The specific preparation steps are as follows: (1) Heat the Zn-8Al alloy to 500℃ to melt it, stir and keep it warm for 30 minutes, then remove the slag and pour it into the hopper.

[0156] (2) Open the valve to inject the molten metal into the barrel in a measured amount, control the temperature at 500℃, and keep the molten metal in a fully liquid state.

[0157] (3) Apply release agent to the inner wall of the mold cavity where the fixed mold and the moving mold are located, close the fixed mold and the moving mold and apply clamping force.

[0158] (4) Turn on the vacuum pump to extract the air from the mold cavity and create a negative pressure in the mold cavity.

[0159] (5) Start the pressurizing component to apply pressure to the molten metal in the barrel, so that the molten metal is injected at high speed through the flow channel and fills the mold cavity.

[0160] (6) After cooling to room temperature, the moving mold retracts and separates from the fixed mold, and the head of the ultrasonic pull rod hooks the solidified material and product in the flow channel and is carried away from the fixed mold.

[0161] (7) The ultrasonic ejector rod pushes the part out under the action of the push rod. The part and the solidified material are then separated manually. The above steps can be repeated for continuous production.

[0162] Comparative Example 8 This comparative example is similar to Example 2, preparing a standard tensile specimen of Zn-10Al alloy. The difference is that ultrasonic vibration is not applied in this comparative example. The specific preparation steps are as follows: (1) Heat the Zn-10Al alloy to 500℃ to melt it, stir and keep it warm for 30 minutes, then remove the slag and pour it into the hopper.

[0163] (2) Open the valve to inject the molten metal into the barrel in a measured amount, control the temperature at 500℃, and keep the molten metal in a fully liquid state.

[0164] (3) Apply release agent to the inner wall of the mold cavity where the fixed mold and the moving mold are located, close the fixed mold and the moving mold and apply clamping force.

[0165] (4) Turn on the vacuum pump to extract the air from the mold cavity and create a negative pressure in the mold cavity.

[0166] (5) Start the pressurizing component to apply pressure to the molten metal in the barrel, so that the molten metal is injected at high speed through the flow channel and fills the mold cavity.

[0167] (6) After cooling to room temperature, the moving mold retracts and separates from the fixed mold, and the head of the ultrasonic pull rod hooks the solidified material and product in the flow channel and is carried away from the fixed mold.

[0168] (7) The ultrasonic ejector rod pushes the part out under the action of the push rod. The part and the solidified material are then separated manually. The above steps can be repeated for continuous production.

[0169] In each embodiment, the vibration power was selected through numerical simulation and experimentation.

[0170] like Figure 8 The image shown is a physical outline of the die-cast part. Figure 9 The dimensions of the die-cast parts are shown, and some deviations are allowed within the die-casting accuracy range. The dimensions and shape of the die-cast parts are based on the standard tensile specimens in the national standard GB / T 228.1-2021 "Metallic Materials - Tensile Testing". The die-cast parts are directly used to test tensile strength and elongation after fracture to characterize the mechanical properties of the prepared materials.

[0171] The methods for characterizing the microstructure and properties of the materials used in each embodiment and comparative example are as follows: (1) Microstructure observation and analysis: Microstructure observation was performed using a Leica Microsystems DMi8C intelligent digital inverted metallurgical microscope (OM). The elemental composition of the aluminum alloy was analyzed by SEM and EDS using an Apreo 2S HiVac high-resolution field emission scanning electron microscope. To facilitate observation of the morphology of α-Al, the microstructure images of the hypoeutectic alloy were processed using ImageJ software to change the color of α-Al to black, thus more clearly distinguishing the α-Al grains, dendrite main axes, and secondary dendrites.

[0172] (2) Tensile strength and elongation after fracture: According to the national standard GB / T 228.1-2010, the strength of the prepared material was tested using a universal testing machine from Shanghai Hualong, with a tensile rate of 0.6 mm / min.

[0173] like Figure 10The diagram shows the Al-Si binary phase diagram. At room temperature, aluminum-silicon alloys contain only two phases: αAl and Si. These alloys are eutectic alloys with a Si content of 12.6%. When the Si content is less than 12.6%, they are hypoeutectic alloys. The chemical structure of hypoeutectic alloys consists of the pre-precipitated αAl phase combined with eutectic (αAl+Si). The pre-precipitated αAl phase has sufficient time to grow. Without intervention, the pre-precipitated αAl phase will grow into a coarse dendritic structure, leading to brittleness and decreased strength. When the Si content is greater than 12.6%, they are hypereutectic alloys. The chemical structure of hypereutectic alloys consists of the pre-precipitated Si phase combined with eutectic (αAl+Si). The inventors discovered that the pre-precipitated Si phase has sufficient time to grow. Without intervention, the pre-precipitated Si phase will grow into a coarse, blocky shape with sharp edges, causing the alloy matrix to be fractured and reducing the alloy's strength. This patent addresses the problems of hypoeutectic and hypereutectic Al-Si by applying ultrasonic vibration when the pre-precipitated phase appears, thereby refining the pre-precipitated phase under ultrasonic cavitation.

[0174] like Figure 11 The figure shows a binary phase diagram of the Zn-Al system. As can be seen from the diagram, the Al content at the eutectic point of the Zn-Al alloy is approximately 5% (mass percentage), and its melting point is 382℃. When the Al content is less than 5%, the phase composition of the alloy at room temperature is (α+η), where α is the Al-based solid solution formed by Zn dissolving in Al, collectively referred to as α-Al; η is the Zn-based solid solution formed by a small amount of Al dissolving in Zn, collectively referred to as η-Zn. When the Al content is greater than 5%, the phase composition of the alloy at room temperature is still (α+η), but the α phase is transformed from the β phase of β(ZnAl) through a eutectoid reaction at 443℃. β(ZnAl) is an ordered solid solution based on ZnAl, belonging to a face-centered cubic lattice structure. The β phase only exists in the intermediate temperature range (443℃-275℃) and undergoes a eutectoid transformation at the eutectoid temperature during cooling. Therefore, the β phase should not exist at room temperature. Compared with the αAl phase obtained by direct eutectic reaction, the α phase derived from eutectoid transformation has a larger Zn content. Therefore, the microstructure and crystal size of the αAl phase directly affect the mechanical properties of the material and the component.

[0175] like Figure 12 and Figure 13 As shown, Figure 12 The microstructure of the Al-6Si alloy casting prepared in Example 1 is mainly composed of α-Al phase and eutectic Si phase (where the black structure is α-Al and the white needle-like structure is Si). Figure 13 To illustrate the microstructure of the alloy casting prepared in Comparative Example 1, the 200W ultrasonic wave used in Example 1 effectively refined α-Al, forming continuous α-Al equiaxed crystals. The α-Al crystals in Comparative Example 1 were relatively coarse and exhibited a dendritic crystal morphology.

[0176] like Figure 14 and Figure 15 As shown, Figure 14 The microstructure morphology of the Al-2Si alloy die-cast part prepared in Example 2 is shown. Figure 15 The image shows the microstructure of the Al-2Si alloy die-cast part prepared in Comparative Example 2. The Al-2Si alloy is mainly composed of α-Al and Si phases, with the black structure being α-Al and the white needle-like network structure being Si. The 300W ultrasonic waves used in Example 2 effectively refined the α-Al and promoted the formation of continuous α-Al equiaxed crystals in the alloy.

[0177] like Figure 16 and Figure 17 As shown, Figure 16 The microstructure of the as-cast 6201 alloy in Example 3 is shown. Figure 17 As a microstructure of Comparative Example 3, after being treated with ultrasound at 400W in Example 3, the α-Al phase of the sample exhibited an equiaxed grain morphology, and the grains were significantly smaller than those of Comparative Example 3.

[0178] like Figure 18 and Figure 19 As shown, Figure 18 The microstructure of the die-cast Al-20Si alloy in Example 4 is shown. Figure 19 The microstructure of die-cast Al-20Si in Comparative Example 4 is shown. In Example 4, the primary silicon was well refined and rounded after being treated with 500W ultrasound, resulting in reduced polygonal shape, blunted sharp corners, and large blocks being broken into multiple smaller pieces. In Comparative Example 4, without ultrasound treatment, the primary silicon was in coarse, blocky form with a polygonal shape.

[0179] like Figure 20 and Figure 21 As shown, Figure 20 The microstructure of the die-cast Zn-4Al alloy in Example 5 shows that the phase composition of the alloy at room temperature is αAl + ηZn, where αAl is an aluminum solid solution formed directly by a liquid eutectic reaction. Figure 21 The microstructure of the die-cast Zn-4Al alloy in Comparative Example 5 is shown. Figure 20 and Figure 21 In Example 5, the white, elliptical phase is αAl. Due to the application of 550W ultrasound, the αAl phase grains were significantly refined, exhibiting a dispersed distribution. In Comparative Example 5, without ultrasound, the αAl phase exhibited a coarse dendritic morphology. The morphology and size of the αAl phase in the alloy largely determine the strength of the zinc-aluminum alloy and play a crucial role in improving its strength.

[0180] like Figure 22 and Figure 23As shown, Figure 22 The microstructure of the die-cast Zn-6Al alloy in Example 6 is shown. Figure 22 The microstructure of the die-cast Zn-6Al alloy in Comparative Example 6 is shown. Since the Al content in the Zn-6Al alloy is greater than 5%, the alloy phase composition at room temperature is αAl + ηZn. The αAl phase is derived from the β phase (ZnAl) formed by the eutectoid reaction at 443℃. The β phase only exists in the intermediate temperature range (443℃-275℃) and undergoes a eutectoid transformation at the eutectoid temperature during cooling; therefore, the β phase should not exist at room temperature. Compared to the αAl phase obtained from the direct eutectic reaction, the α phase derived from the eutectoid transformation has a larger Zn content, thus... Figure 22 and Figure 23 The αAl phase formed in it is darker in color (compared to...). Figure 20 and Figure 21 (Comparative Example 6). In Example 6, due to the application of 600W ultrasound, the η-phase dendrites were broken up and exhibited a diffuse distribution. In Comparative Example 6, without ultrasound, the η-phase exhibited a coarse dendritic morphology. The morphology and size of the η-phase in the alloy largely determine the strength of the zinc-aluminum alloy and play a very important role in improving the strength of the zinc-aluminum alloy.

[0181] like Figure 24 and Figure 25 As shown, Figure 24 The microstructure of the die-cast Zn-8Al alloy in Example 7 is shown. Figure 25 The microstructure of the die-cast Zn-8Al alloy in Comparative Example 7 is shown. In Example 7, due to the application of ultrasound at 700W, the η-phase dendrites were broken up and exhibited a dispersed morphology. In Comparative Example 7, without ultrasound treatment, the η-phase exhibited a coarse dendritic morphology. The morphology and size of the η-phase in the alloy largely determine the strength of the zinc-aluminum alloy and play a very important role in improving the strength of the zinc-aluminum alloy.

[0182] like Figure 26 and Figure 27 As shown, Figure 26 The microstructure of the die-cast Zn-10Al alloy in Example 8 is shown. Figure 27 The microstructure of the die-cast Zn-10Al alloy in Comparative Example 8 is shown. In Example 8, due to the application of ultrasound at 800W, the η-phase dendrites were broken up and exhibited a dispersed morphology. In Comparative Example 8, without ultrasound treatment, the η-phase exhibited a coarse dendritic morphology. The morphology and size of the η-phase in the alloy largely determine the strength of the zinc-aluminum alloy and play a very important role in improving the strength of the zinc-aluminum alloy.

[0183]

[0184] Table 1 Mechanical properties of each embodiment and comparative example As shown in Table 1, for Al alloys, including Al-Si alloys and 6201 alloys, Examples 1 to 4 used a non-ferrous metal ultrasonic-assisted vacuum die casting device. The ultrasonic vibration acted on the semi-solid metal slurry in the mold cavity, and the resulting castings had higher elongation after fracture and tensile strength than Comparative Examples 1 to 4. For zinc-aluminum alloys, including Zn-3Al, Zn-6Al, Zn-8Al, and Zn-10Al, Examples 5 to 8 used a non-ferrous metal ultrasonic-assisted vacuum die casting device. The ultrasonic vibration acted on the semi-solid Zn-3Al metal slurry in the mold cavity. Due to the excellent grain refinement effect, the castings had higher elongation after fracture and tensile strength than Comparative Examples 5 to 8.

[0185] Obviously, the above embodiments of the present invention are merely examples for clearly illustrating the present invention, and are not intended to limit the implementation of the present invention. Those skilled in the art can make other variations or modifications based on the above description. It is neither necessary nor possible to exhaustively describe all embodiments here. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the scope of protection of the claims of the present invention.

Claims

1. A non-ferrous metal ultrasonic-assisted vacuum die-casting molding device, characterized in that: The system includes a molding die (1), a casting system (2), a vacuum system (3), and a vibration demolding system (4). The molding die (1) forms a mold cavity (11). The casting system (2) is connected to the molding die (1) and is used to inject liquid metal into the mold cavity (11). The vacuum system (3) is connected to the molding die (1) and is used to evacuate the mold cavity (11). The vibration demolding system (4) includes an ultrasonic component (41) and a driving component (42). The fixed end of the ultrasonic component (41) is fixedly connected to the driving component (42), and the output end of the ultrasonic component (41) is connected to the molding die (1). The driving component (42) is used to drive the ultrasonic component (41) to move and to drive the molding die (1) to open and close.

2. The non-ferrous metal ultrasonic-assisted vacuum die-casting molding device according to claim 1, characterized in that: The molding die (1) includes a fixed die (12) and a moving die (13). The fixed die (12) and the moving die (13) are joined together to form the mold cavity (11). The casting system (2) is connected to the fixed die (12) and communicates with the mold cavity (11). The vacuum system (3) is connected to the fixed die (12) and communicates with the mold cavity (11). The vibration demolding system (4) is connected to the moving die (13).

3. The non-ferrous metal ultrasonic-assisted vacuum die-casting molding apparatus according to claim 2, characterized in that: The casting system (2) includes a hopper (21), a cylinder (22), a heating component (23), a pressurizing component (24), and a valve (25). The cylinder (22) is fixedly connected to the fixed mold (12) and communicates with the mold cavity (11). The hopper (21) is connected to the cylinder (22). The valve (25) is provided at the connection outlet between the hopper (21) and the cylinder (22). The heating component (23) is connected to the cylinder (22). The pressurizing component (24) is movably connected to the cylinder (22).

4. The non-ferrous metal ultrasonic-assisted vacuum die-casting molding apparatus according to claim 3, characterized in that: The heating element (23) is a resistance wire or heating coil arranged around the barrel (22).

5. The ultrasonic-assisted vacuum die-casting apparatus for non-ferrous metals according to claim 2, characterized in that: The output end of the ultrasonic component (41) is fixedly connected to the moving model (13).

6. The ultrasonic-assisted vacuum die-casting apparatus for non-ferrous metals according to claim 5, characterized in that: The ultrasonic component (41) includes an amplitude transformer (411), an ultrasonic tool head (412), a transducer (413), and an ultrasonic generator (414). One end of the amplitude transformer (411) is fixedly connected to the drive component (42), and the other end of the amplitude transformer (411) is connected to the ultrasonic tool head (412). The transducer (413) is provided on the amplitude transformer (411), and the ultrasonic generator (414) is electrically connected to the transducer (413). A first mounting hole (131) is provided through the moving mold (13). The amplitude transformer (411) passes through the first mounting hole (131) and is fixedly connected to the moving mold (13). The end of the ultrasonic tool head (412) away from the amplitude transformer (411) is sealed at the end of the first mounting hole (131) near the inner wall of the mold cavity (11).

7. The non-ferrous metal ultrasonic-assisted vacuum die-casting apparatus according to claim 6, characterized in that: The ultrasonic component (41) also includes an ultrasonic pull rod (415). A second mounting hole (132) is provided through the moving mold (13). One end of the ultrasonic pull rod (415) is fixedly connected to the drive component (42). The other end of the ultrasonic pull rod (415) passes through the second mounting hole (132) and is fixedly connected to the moving mold (13). The end of the ultrasonic pull rod (415) connected to the moving mold (13) extends into the mold cavity (11) and has a hook-shaped part (4151).

8. The ultrasonic-assisted vacuum die-casting apparatus for non-ferrous metals according to claim 5, characterized in that: The drive assembly (42) includes a first fixing plate (421), a second fixing plate (422), and a push rod (423). The first fixing plate (421) and the second fixing plate (422) are fixedly connected. The first fixing plate (421) has a push hole (4211). The push rod (423) passes through the push hole (4211) and is fixedly connected to the second fixing plate (422). The second fixing plate (422) has multiple push rod holes (4221). One end of the amplitude transformer (411) and the ultrasonic pulling rod (415) are fixedly connected to the push rod holes (4221).

9. The ultrasonic-assisted vacuum die-casting apparatus for non-ferrous metals according to claim 2, characterized in that: The vacuum system (3) includes a vacuum pump (31) and a vacuum channel (32). The vacuum channel (32) passes through the fixed mold (12) and is connected to the mold cavity (11). The output end of the vacuum pump (31) is connected to the vacuum channel (32).

10. A method for ultrasonic-assisted vacuum die casting of non-ferrous metals, implemented using the apparatus described in any one of claims 1 to 9, characterized in that: include: The raw materials are mixed in proportion and heated to form liquid raw materials. A vacuum system (3) is used to create a negative pressure in the mold cavity (11) to inject the liquid raw materials into the mold cavity (11). When the liquid raw materials in the mold cavity (11) cool down to the semi-solid temperature range, the raw materials in the mold cavity (11) are vibrated by the vibration demolding system (4). When the liquid raw materials in the mold cavity (11) continue to cool down to below the semi-solid temperature range, the vibration is stopped. After complete cooling, the product is demolded.

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