Array-Spraying Additive Manufacturing for Large Aluminum Ingots
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Solution Overview
Problem
Conventional methods for manufacturing large-sized aluminum alloy ingots face challenges such as macroscopic segregation, internal stress, porosity, and low production efficiency, making it difficult to produce ingots with a segregation-free equiaxed crystal structure.
Innovation Solution
An array-spraying additive manufacturing apparatus and method that generates negative pressure to form a stable continuous metal liquid column, using an array of nozzles to evenly disperse large-volume liquid aluminum and a rapidly moving condensing table to solidify it into large-area ingots with an equiaxed crystal structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If conventional hot top casting or direct chill casting is used, then large-size aluminum alloy ingots can be produced, but macroscopic segregation and internal stress occur leading to cracking and low yield
Solution Approach 1:
The continuous metal stream is segmented into droplets through a spray nozzle array, creating numerous small liquid metal streams that solidify independently. This segmentation prevents the formation of large columnar crystal zones and macroscopic segregation that occur in conventional casting of large ingots.
Solution Approach 2:
The invention transitions from conventional horizontal or vertical casting to a three-dimensional spray deposition process where molten metal is sprayed from multiple nozzles arranged in arrays. The condensing table moves in three dimensions (X, Y, Z axes) to build the ingot layer by layer, enabling large-size production with equiaxed crystal structure throughout.
2Manufacturing precision
If spray forming is used to avoid macroscopic segregation, then ingots without segregation can be produced, but high porosity and severe oxidation occur
Solution Approach 1:
The spray chamber is filled with inert gas (such as nitrogen or argon) to create a protective atmosphere that prevents oxidation of the molten metal droplets during spraying and solidification. This eliminates the severe oxidation problem that occurs in conventional spray forming performed in atmospheric conditions.
3Manufacturing precision
If selective laser remelting is used to achieve ideal solidified structure, then equiaxed crystal structure can be obtained, but production efficiency is low and cost is high
Solution Approach 1:
The invention replaces the selective laser remelting process (which uses high-energy laser beams to melt and resolidify metal layer by layer) with a direct spray deposition method. Molten metal is sprayed directly onto the condensing table where it solidifies naturally, forming equiaxed crystals without requiring laser energy input. This mechanical substitution dramatically increases production efficiency while maintaining the desired equiaxed crystal structure.
4Ease of operation
If metal droplet additive manufacturing with magnetic field is used, then charged metal droplets can be controlled, but forming efficiency is too low for large-sized ingot production
Solution Approach 1:
The invention extracts and eliminates the magnetic field control system from the metal droplet generation process. Instead of using charged droplets requiring complex magnetic field manipulation, the patent uses neutral molten metal sprayed through conventional spray nozzles. This simplification removes the bottleneck of low forming efficiency associated with magnetic field control while maintaining adequate droplet control through nozzle geometry and spray parameters.
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 method achieves high production efficiency and produces ultra-large-sized aluminum alloy ingots with a dense, segregation-free equiaxed crystal structure, overcoming the limitations of conventional casting methods.
Implementation Method 1
sprays large-volume melts by generating negative pressure so as to form a stable continuous metal liquid column
Implementation Method 2
through a design of an array arrangement of multiple nozzles, large-volume liquid aluminum evenly dispersed to form dozens to even hundreds of continuous liquid flows
Implementation Method 3
enables, by combining three-dimensional movement of a rapid condensing table below, large-area spreading of the thin liquid aluminum which is then continuously solidified to form ingots
Data Source
AI summary
An array-spraying additive manufacturing apparatus and method for manufacturing a large-sized equiaxed crystal aluminum alloy ingot, comprising: a liquid aluminum spraying mechanism having array nozzles disposed in an atmospheric pressure chamber, a movable condensing mechanism disposed in the atmospheric pressure chamber below the liquid aluminum spraying mechanism, and a control mechanism. The control mechanism sends an upward guiding command to a release mechanism and issues a three-dimensional movement command to the movable condensing mechanism, such that liquid aluminum in the liquid aluminum spraying mechanism is sprayed at the surface of the movable condensing mechanism in a continuous array of liquid flows according to a preset path and is rapidly condensed to form an ingot. Also disclosed is an additive manufacturing method employing the apparatus.