Pivotable Mould for Monoaxial Solidification
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Solution Overview
Problem
Existing methods for producing metal alloy ingots with monoaxial solidification are complex and prone to macro-segregation and crack sensitivity, particularly in high-strength aluminium alloys.
Innovation Solution
A method involving a pivotable open-ended mould with temperature control and directional cooling, allowing for monoaxial solidification by rotating the mould to direct molten metal flow and control cooling, eliminating the need for cores and reducing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional casting methods with cores and complex cooling systems are used, then monoaxial solidification can be achieved, but the device complexity and process complexity increase significantly
Solution Approach 1:
The patent removes cores and core packages from the mould cavity, eliminating the need for complex core positioning and removal mechanisms. The extraction of these unnecessary elements simplifies the mould structure while maintaining monoaxial solidification capability through direct bottom cooling.
Solution Approach 2:
Instead of cooling the mould from the sides or top as in conventional methods, the patent inverts the cooling approach by applying temperature control means directly to the bottom plate. This inversion of the cooling direction enables monoaxial solidification from the bottom upward, simplifying the overall mould design.
2Reliability
If conventional horizontal or vertical mould positioning is used, then casting can be performed, but macro-segregation and crack sensitivity increase in high-strength aluminium alloys
Solution Approach 1:
The patent introduces a pivotable mould that can dynamically change its opening direction between upward, sideways, and downward positions. This dynamic positioning capability allows optimization of metal flow patterns during filling, reducing macro-segregation and crack sensitivity in high-strength aluminium alloys while maintaining manufacturing simplicity.
3Manufacturing precision
If complex cooling systems with multiple cooling zones are used, then solidification control is improved, but the device complexity and cost increase
Solution Approach 1:
The patent applies temperature control means specifically to the bottom plate where they are most needed for monoaxial solidification. This localized cooling approach provides effective solidification control without requiring complex multi-zone cooling systems throughout the entire mould structure.
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 method simplifies the casting process, reduces macro-segregation, and enhances the production of crack-resistant ingots, particularly for high-strength aluminium alloys, while offering flexibility in cooling conditions and cost efficiency.
Implementation Method 1
the bottom plate of the mould is provided with temperature control means, in particular with coolant means to distract in a controlled manner the heat away from the solidifying metal through the bottom plate
Implementation Method 2
the molten metal in the open-ended mould is cooled directionally through its thickness where the solidification front remains substantially monoaxial and substantially parallel to the bottom plate of the mould
Implementation Method 3
rotating the open-ended mould together with the casting container around the horizontal axis for approximately 45° to 180°, preferably, 90° or 180°, as the case may be, from a position whereby the mould opening points side-wards or down-wards to a position whereby the mould opening points upwards such that the molten metal is conveyed
Data Source
AI summary
A method of casting a metal alloy ingot, including the following steps: providing a one side open-ended mould including a plurality of sides and a bottom plate defining a mould cavity with a mould opening, the open-ended mould being pivotable around a horizontal rotational axis between a position so that the mould opening points upwards and a position so that the mould opening points side-wards or down-wards; positioning the open-ended mould such that the mould opening points side-wards or down-wards; providing a casting container with an upwardly positioned aperture; filling the casting container with molten metal for one casting operation; coupling the casting container to the open-ended mould so that the casting container is located below the mould while the mould opening points side-wards or down-wards; rotating the open-ended mould together with the casting container around the horizontal rotational axis for approximately 90° to 180° from a position whereby the mould opening points side-wards or down-wards to a position whereby the mould opening points upwards such that the molten metal is conveyed through the mould opening into the open-ended mould until reaching a desired thickness, whereby the molten metal in the open-ended mould is cooled directionally through its thickness where the solidification front remains substantially monoaxial.