Differential Pressure Casting Mold for Amorphous Metal Sheets
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Solution Overview
Problem
Existing casting molds for metal sheets, particularly amorphous alloys, face challenges in uniformly casting sheets due to frictional forces and non-uniform cooling, leading to defects and irregular surfaces, and require complex configurations and high costs.
Innovation Solution
A differential pressure type casting mold design that changes the flow direction of molten metal to uniformly fill the mold cavity, using a passageway and suction portions connected to a vacuum source to minimize friction and ensure uniform cooling, allowing for the production of metal sheets with various shapes without altering the basic structure of the mold.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If molten metal is rapidly drawn into the mold cavity using negative pressure, then the cooling speed is improved and amorphous structure is achieved, but frictional force in the narrow passageway prevents quick flow of molten metal
Solution Approach 1:
The invention divides the single narrow passageway into multiple passageways (first passageway and second passageway) that extend in different directions. This segmentation allows molten metal to flow through multiple parallel paths, reducing frictional resistance and improving flow speed while maintaining the rapid cooling capability needed for amorphous structure formation.
Solution Approach 2:
The invention creates different flow conditions in different regions of the mold cavity by having passageways extend in different directions. The first passageway extends in a first direction and the second passageway extends in a second direction different from the first direction, allowing localized optimization of metal flow distribution and reducing frictional effects in each region.
2Ease of manufacture
If a differential pressure type casting method is used to cast metal sheets, then the basic mold structure is maintained, but non-uniform cooling and friction lead to defects and irregular surfaces
Solution Approach 1:
The invention segments the cooling and flow distribution system into multiple directional passageways within the mold body. This allows uniform distribution of molten metal and cooling fluid across different regions, eliminating non-uniform cooling and friction-related defects while maintaining the basic differential pressure casting structure.
Solution Approach 2:
The invention uses asymmetric passageway arrangements where the first passageway extends in a first direction and the second passageway extends in a second direction different from the first direction. This asymmetric configuration optimizes flow distribution and cooling uniformity across the mold cavity, preventing defects and irregular surfaces in the cast metal sheet.
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
The solution enables the production of uniform, amorphous metal sheets with improved cooling performance, reducing defects and costs by maintaining the basic configuration of the casting mold and allowing for the casting of large-area sheets with precise control.
Implementation Method 1
a method is mainly used which casts an amorphous alloy specimen by rapidly drawing the molten metal into the mold cavity by using negative pressure made by suction
Implementation Method 2
by solidifying the molten metal by transferring heat to a main mold body having high thermal conductivity
Data Source
AI summary
The present invention relates to a casting mold for a metal sheet by drawing molten metal into a mold cavity and cooling the molten metal, and the casting mold according to the present invention includes: a support portion at an upper side on which molten metal is disposed or a solid metal is placed and melted; a mold cavity at a lower side in which the metal sheet is formed as the molten metal is drawn from the support portion while filling the mold cavity and cooled; and a passageway through which the molten metal is drawn into the mold cavity from the support portion, in which the mold cavity includes a first surface at the upper side which communicates with the passageway, and a second surface at the lower side which faces the first surface, a plurality of suction portions for drawing the molten metal are formed in the second surface and extended downward from the second surface, the suction portions are connected to a vacuum source and configured to draw the molten metal by suctioning air from the mold cavity, and a blocking member, which is in contact with the second surface or the suction portions to prevent a leakage of the molten metal and allow an air flow, is disposed on the suction portions in the mold cavity.