Amorphous Alloy Ribbon Nozzle Clogging Prevention
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Solution Overview
Problem
Existing methods for producing amorphous alloy ribbons face challenges in achieving high producibility due to issues with melt feeding and nozzle clogging, leading to interruptions in the casting process.
Innovation Solution
Incorporating specific amounts of manganese (Mn) and sulfur (S) into the Fe—B—Si—C-type amorphous alloy composition, which forms a compound MnS that suppresses the growth of nonmetal oxides, thereby preventing nozzle clogging and allowing for continuous melt feeding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional amorphous alloy composition is used, then basic magnetic properties are achieved, but nozzle clogging occurs due to nonmetal oxide growth, interrupting continuous production
Solution Approach 1:
The invention changes the chemical composition parameters by adding specific amounts of Mn (0.01-0.10 mass%) and S (0.01-0.05 mass%) to the conventional Fe-Si-B-C alloy system. This parameter modification suppresses nonmetal oxide growth through MnS formation, preventing nozzle clogging and enabling continuous production without interrupting the casting process
Solution Approach 2:
MnS acts as an intermediary substance that suppresses the growth of nonmetal oxides. The MnS compound forms in the melt and interferes with oxide particle aggregation, preventing them from growing large enough to clog the discharge slit, thus mediating between the oxide formation process and the nozzle flow
2Productivity
If melt feeding amount and pressure are increased to improve production speed, then productivity increases, but nozzle clogging risk increases due to higher velocity and turbulence
Solution Approach 1:
The invention converts the potentially harmful effect of high-velocity melt flow into a beneficial outcome. By adding Mn and S to suppress oxide growth, the invention enables higher melt feeding rates and pressures without increasing clogging risk, as the suppressed oxide particles cannot aggregate into clogging-sized fragments even under turbulent flow conditions
3Productivity
If production duration is extended to improve efficiency, then productivity increases, but nonmetal oxide accumulates and clogs the discharge slit, interrupting the process
Solution Approach 1:
The invention performs preliminary action by adding Mn and S to the alloy composition before casting begins. This pre-prepared chemical environment suppresses oxide growth throughout the entire casting process, allowing extended production duration without the progressive clogging that would normally occur over time
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enables stable and continuous production of amorphous alloy ribbons by preventing occlusion of the melt discharge slit, improving fluidity and maintaining production over extended periods.
Implementation Method 1
Incorporating specific amounts of manganese (Mn) and sulfur (S) into the Fe—B—Si—C-type amorphous alloy composition, which forms a compound MnS that suppresses the growth of nonmetal oxides
Implementation Method 2
forms a compound MnS that suppresses the growth of nonmetal oxides, thereby preventing nozzle clogging
Implementation Method 3
an alloy material in a molten state (melt) is discharged onto a rotating chill roll, and the discharged melt is quenched and solidified on a surface of the chill roll
Data Source
AI summary
The present invention achieves an object of continuously supplying a melt from a melt nozzle over a long period of time by adjusting the contents of Mn and S in an Fe—B—Si—C-type amorphous alloy ribbon. An amorphous alloy ribbon of the present invention includes a composition containing Fe, Si, B, C, Mn, S, and inevitable impurities, the composition containing, with respect to 100.0 atm % of the total amount of Fe, Si, B, and C, 3.0 atm % or more and 10.0 atm % or less of Si, 10.0 atm % or more and 15.0 atm % or less of B, and 0.2 atm % or more and 0.4 atm % or less of C, the amorphous alloy ribbon having a content ratio of Mn of more than 0.12 mass % and less than 0.15 mass %, and a content ratio of S of 0.0036 mass % or more and less than 0.0045 mass %, the amorphous alloy ribbon having a thickness of 10 μm or more and 40 μm or less, and a width of 100 mm or more and 300 mm or less.