Foundry Furnace Asynchronous Curving Supercooling
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Solution Overview
Problem
Conventional foundry furnaces cannot simultaneously produce single crystal, fine crystal, and non-crystal metal products, with single-crystal furnaces suffering from dendritic crystal issues, fine-crystal furnaces failing to achieve uniformity and stability, and non-crystal production lacking in block form due to insufficient supercooling and magnetic field intensity.
Innovation Solution
A foundry furnace and method employing asynchronous curving of space-time supercooling, utilizing a casting-shell mold chamber with opposing magnetic fields generated by superconducting coils and a heating coil, allowing for deep supercooling and intense magnetic fields to achieve simultaneous casting of single, fine, and non-crystal metals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional single-crystal furnaces use dendritic crystal growth mode, then single crystal can be produced, but grain boundary and component segregation appear deteriorating the quality
Solution Approach 1:
The patent changes the solidification parameters by creating deep supercooling conditions (temperature gradient) combined with intense magnetic field, transforming the solidification mode from dendritic to planar, thereby eliminating grain boundaries and component segregation
Solution Approach 2:
The patent employs periodic alternation between heating and magnetic field application, and between different solidification stages, to control the crystallization process and achieve planar solidification without dendritic defects
2Manufacturing precision
If conventional fine-crystal furnaces increase solidification speed, then fine crystals can be produced, but uniformity and stability of grain structure deteriorate
Solution Approach 1:
The patent changes the thermal parameters by implementing deep supercooling before solidification, creating a large temperature gradient that enables fast solidification while maintaining uniform fine isometric grain structure through controlled nucleation
Solution Approach 2:
The patent performs preliminary deep supercooling of the metal liquid before initiating solidification, preparing the liquid state with sufficient undercooling to ensure uniform nucleation and fine grain formation during subsequent rapid solidification
3Manufacturing precision
If conventional methods produce non-crystal metals, then non-crystal state can be achieved, but products are limited to thin bands below 1mm thickness
Solution Approach 1:
The patent changes the thermal and magnetic parameters by applying intense magnetic field during deep supercooling, enabling the production of thick-block non-crystal metal products that exceed conventional thickness limitations while maintaining non-crystal structure and properties
4Adaptability or versatility
If dual-function foundry furnaces heat coil and generate static magnetic field simultaneously, then both heating and magnetic field functions are provided, but magnetic field intensity is insufficient
Solution Approach 1:
The patent segments the heating and magnetic field generation functions into separate components - heating coil for thermal control and superconducting coils for intense magnetic field generation, allowing each to operate at full capacity without compromising the other
Solution Approach 2:
The patent replaces conventional electromagnetic coils with superconducting coils for magnetic field generation, eliminating resistive heating losses and enabling much higher magnetic field intensity while maintaining system versatility
5Manufacturing precision
If conventional furnaces cannot achieve deep supercooling, then metal liquid can be processed, but supercooling degree is insufficient for high-quality casting
Solution Approach 1:
The patent changes the thermal parameters by implementing deep supercooling through controlled heat extraction and intense magnetic field application, achieving temperature gradients sufficient for planar solidification and high-quality crystal formation
Solution Approach 2:
The patent employs periodic control of heating and cooling rates, along with magnetic field application timing, to achieve and maintain deep supercooling conditions necessary for high-precision casting
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
Enables the production of high-quality single crystals with planar solidification, fine crystals with uniform isometric grains, and non-crystal metals with reduced storage energy and improved compactness, exceeding industrial standards in terms of quality and uniformity.
Implementation Method 1
a heating coil winding... (35), a first cooling pipeline (37)... The heating coil winding (35) forms a forward-directional static-magnetic-field heating zone
Implementation Method 2
a first superconducting coil (41)... a second superconducting coil (53)... the first superconducting coil (41) and the heating coil winding (35) form a forward-directional static-magnetic-field heating zone
Implementation Method 3
the directions of a magnetic field generated by the first superconducting coil and a magnetic field generated by the second superconducting coil are opposite
Implementation Method 4
a first thermal-shield assembly, a first superconducting coil (41)... the first thermal-shield assembly is provided at an outside of the heating coil winding
Implementation Method 5
a first cooling pipeline (37)... (47)... the first cooling pipeline (37) and the second cooling pipeline (47) are respectively provided within the housing (42)
Data Source
AI summary
The present disclosure discloses a shell mold chamber, a foundry furnace and a method for casting single crystal, fine crystal and non-crystal, which employ the technique of asynchronous-curving supercooling, and belongs to the technical field of precise casting apparatuses. Such a three-function foundry furnace includes a heating coil winding, a first thermal-shield assembly, a first superconducting coil, a second thermal-shield assembly and a second superconducting coil; and the first superconducting coil is provided at an inside of the first thermal-shield assembly, and the second superconducting coil is provided at an inside of the second thermal-shield assembly; and directions of a magnetic field generated by the first superconducting coil and a magnetic field generated by the second superconducting coil are opposite; and the first superconducting coil and the heating coil winding form a forward-directional static-magnetic-field heating zone, and the second superconducting coil forms a reverse-directional static-magnetic-field zone.