Mold Shell Deflection for Single-Crystal MSM Alloy Orientation
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Solution Overview
Problem
Current methods for producing single-crystal MSM bodies result in stochastic crystal orientation, leading to inefficient production with significant waste and the need for costly seed crystals, limiting the achievable dimensions of MSM elements.
Innovation Solution
A method that involves introducing molten MSM alloy into a specially designed mold shell with a deflected solidification path, allowing for controlled crystal orientation along the longitudinal axis, eliminating the need for seed crystals and reducing waste by aligning the crystal structure during solidification.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a molten alloy material is introduced into a mold shell and solidified using conventional methods, then a single-crystal MSM body is produced, but the crystal orientation is stochastic and cannot be predetermined, leading to significant waste and the need for costly seed crystals
Solution Approach 1:
The mold shell is pre-designed with a specific geometric configuration including a deflection area that will guide and control the crystal growth direction during solidification. The longitudinal axis and deflection angle are predetermined in the mold design to achieve the desired crystal orientation without requiring seed crystals or post-processing measurements
Solution Approach 2:
The geometric parameters of the mold shell, particularly the deflection angle and longitudinal axis orientation, are optimized to control the solidification process. By changing the mold geometry parameters, the crystal growth direction is controlled to align with the longitudinal axis, achieving predictable crystal orientation without waste
2Manufacturing precision
If seed crystals are used to influence crystal orientation in monocrystal production, then crystal orientation can be controlled, but the process becomes more complex and expensive with very precise process control requirements
Solution Approach 1:
The seed crystal step is completely removed from the production process. Instead of introducing a separate seed crystal, the mold shell geometry itself serves as the control mechanism for crystal orientation, simplifying the overall process and eliminating the complexity associated with seed crystal handling and placement
Solution Approach 2:
The mold shell serves multiple functions: it contains the molten alloy, controls the solidification process, and guides the crystal growth direction through its geometric configuration. The longitudinal axis and deflection area of the mold shell universally control the crystal orientation without requiring additional seed crystals or complex process steps
3Quantity of substance
If conventional solidification methods are used, then single-crystal MSM bodies can be produced, but the achievable dimensions of MSM elements are limited due to geometric relationships and waste requirements
Solution Approach 1:
The mold shell geometric parameters, including the deflection angle and longitudinal axis, are optimized to maximize the usable material. This allows larger MSM elements to be produced with minimal waste, as the crystal orientation is controlled throughout the entire volume of the mold shell rather than requiring cutting from randomly oriented crystals
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 the production of MSM elements with reduced waste and improved crystal orientation, allowing for larger dimensions and simplified manufacturing processes, making MSM actuators more efficient and scalable.
Implementation Method 1
introducing molten MSM alloy into a specially designed mold shell with a deflected solidification path, allowing for controlled crystal orientation along the longitudinal axis
Implementation Method 2
the crystal to be produced ideally nucleates in monocrystalline form on which the crystal to be produced ideally nucleates in monocrystalline form
Data Source
Figure 1~5
AI summary
The invention relates to a method for producing an MSM actuator element, having a crystal orientation along a first crystal axis, from a monocrystalline MSM body by introducing a molten alloying material into a molding shell and subsequently solidifying the alloying material, comprising the following steps: providing a molding shell which comprises a nucleation region (24), a selector region (26) and a crystal region (28) and is oriented along a longitudinal axis (22) at least in some sections, introducing the molten MSM alloying material, in particular NiMnGa-based alloying material, into the molding shell without providing a separate nucleation crystal, compacting the MSM alloying material by generating a solidification front moving from the nucleation region across the selector region into the crystal region along a solidification path, wherein the solidification path in the crystal region runs along the longitudinal axis, forms a region which is deflected from the longitudinal axis in the selector region, the maximum deflection of which, relative to the longitudinal axis, is greater than a maximum cross-sectional width in the selector region, and the longitudinal axis (22) has an angular deviation of less than 10º, preferably less than 6º, and more preferably less than 3º, from the first crystal axis, and dividing the solidified MSM alloying material into a plurality of MSM actuator elements.