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CA2660940A1 - Solidification microstructure of aggregate molded shaped castings - Google Patents

Solidification microstructure of aggregate molded shaped castings Download PDF

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Publication number
CA2660940A1
CA2660940A1 CA002660940A CA2660940A CA2660940A1 CA 2660940 A1 CA2660940 A1 CA 2660940A1 CA 002660940 A CA002660940 A CA 002660940A CA 2660940 A CA2660940 A CA 2660940A CA 2660940 A1 CA2660940 A1 CA 2660940A1
Authority
CA
Canada
Prior art keywords
solidification microstructure
metal casting
casting
region
microstructure
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
CA002660940A
Other languages
French (fr)
Other versions
CA2660940C (en
Inventor
John R. Grassi
John Campbell
J. Fred Major
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Rio Tinto Alcan International Ltd
Alotech Ltd LLC
Original Assignee
Individual
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Individual filed Critical Individual
Publication of CA2660940A1 publication Critical patent/CA2660940A1/en
Application granted granted Critical
Publication of CA2660940C publication Critical patent/CA2660940C/en
Active legal-status Critical Current
Anticipated expiration legal-status Critical

Links

Classifications

    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
    • C22F1/00—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
    • C22F1/002—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working by rapid cooling or quenching; cooling agents used therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D15/00—Casting using a mould or core of which a part significant to the process is of high thermal conductivity, e.g. chill casting; Moulds or accessories specially adapted therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D21/00—Casting non-ferrous metals or metallic compounds so far as their metallurgical properties are of importance for the casting procedure; Selection of compositions therefor
    • B22D21/002—Castings of light metals
    • B22D21/007—Castings of light metals with low melting point, e.g. Al 659 degrees C, Mg 650 degrees C
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D15/00—Casting using a mould or core of which a part significant to the process is of high thermal conductivity, e.g. chill casting; Moulds or accessories specially adapted therefor
    • B22D15/04—Machines or apparatus for chill casting
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D25/00—Special casting characterised by the nature of the product
    • B22D25/06—Special casting characterised by the nature of the product by its physical properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D27/00—Treating the metal in the mould while it is molten or ductile ; Pressure or vacuum casting
    • B22D27/04—Influencing the temperature of the metal, e.g. by heating or cooling the mould
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D30/00—Cooling castings, not restricted to casting processes covered by a single main group
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D46/00—Controlling, supervising, not restricted to casting covered by a single main group, e.g. for safety reasons
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C21/00—Alloys based on aluminium
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
    • C22F1/00—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
    • C22F1/04—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of aluminium or alloys based thereon

Landscapes

  • Mechanical Engineering (AREA)
  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • Organic Chemistry (AREA)
  • Metallurgy (AREA)
  • Thermal Sciences (AREA)
  • Crystallography & Structural Chemistry (AREA)
  • Physics & Mathematics (AREA)
  • Continuous Casting (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)
  • Mold Materials And Core Materials (AREA)
  • Golf Clubs (AREA)

Abstract

A shaped metal casting made in an aggregate mold comprises fine solidification microstructure that is finer than the solidification microstructure of an analogous metal casting made from conventional molding processes. The solidification microstructure may be up to five times finer than the solidification microstructure of a conventionally prepared casting. In preferred embodiments, as a result of directional solidification, the fine solidification microstructure is substantially continuous from a distal end of the casting to a proximal end of the casting, and exhibits greatly enhanced soundness. Because of the control of the uniformity of freezing of the casting, its properties are substantially uniform.

Claims (28)

1. A shaped metal casting formed in a mold comprising an aggregate by an ablation casting process, the casting comprising a fine solidification microstructure, wherein the fine microstructure comprises dendrites having a dendrite arm spacing of 5 micrometers to 15 micrometers, eutectic phases having a eutectic spacing of 1 micrometer or less, or combinations thereof.
2. The shaped metal casting according to claim 1, wherein the casting comprises about 100% fine solidification microstructure.
3. The shaped metal casting according to claim 1, wherein the fine solidification microstructure is continuous from a distal end of the casting to a proximal end thereof.
4. The shaped metal casting according to claim 1, wherein the fine solidification microstructure is substantially continuous from a distal end of the casting to a proximal end thereof.
5. The shaped metal casting according to claim 1, wherein the casting is substantially free of porosity.
6. The shaped metal casting according to claim 1, further comprising a dual solidification microstructure region comprising (i) a coarse solidification microstructure portion, and (ii) the fine solidification microstructure interspersed within the coarse solidification microstructure portion, wherein the coarse microstructure portion comprises dendrites having a dendrite arm spacing of 20 micrometers to 200 micrometers, eutectic phases having a eutectic spacing of 2 micrometers to 20 micrometers, or combinations thereof.
7. The shaped metal casting according to claim 6, wherein the dual solidification microstructure region is substantially continuous from a distal end of the casting to a proximal end thereof.
8. A metal casting formed in a mold comprising an aggregate via a rapid cooling process and exhibiting a cast microstructure, the microstructure comprising a first region located adjacent a surface of the metal casting, the first region comprising a coarse solidification microstructure; and a second region located internal to the first region, the second region comprising a fine solidification microstructure.
9. The metal casting according to claim 8, wherein the second region is substantially continuous from a distal end of the casting to a proximal end thereof.
10. The metal casting according to claim 8, wherein the second region comprises dendrites having a dendrite arm spacing of about 20 micrometers or less.
11. The metal casting of claim 8, wherein the second region comprises dendrites having a dendrite arm spacing of about 5 to about 15 micrometers.
12. The metal casting of claim 8, wherein the first region comprises dendrites having a dendrite arm spacing of about 20 to about 200 micrometers.
13. The metal casting of claim 8, wherein the casting is substantially free of at least one of (i) shrinkage porosity, and (ii) damaging iron-rich platelets.
14. The metal casting of claim 8, wherein the first region comprises approximately 100% coarse solidification microstructure, and the second region comprises approximately 100% fine solidification microstructure.
15. The metal casting of claim 14 further comprising a third region located between the first and second regions, wherein the third region comprises a dual solidification microstructure comprising (i) one or more coarse solidification microstructure portions, and (ii) one or more fine solidification microstructure portions.
16. The metal casting of claim 15, wherein the one or more coarse solidification microstructure portions of the dual solidification microstructure region comprises dendrites having a dendrite arm spacing of about 20 to about 200 micrometers and the one or more fine solidification microstructure portions of the dual solidification microstructure region comprises dendrites having a dendrite arm spacing of about 15 micrometers or less.
17. The metal casting of claim 15 wherein the third region is substantially continuous throughout a shape of the metal casting.
18. A metal casting formed from a eutectic-containing alloy, the casting comprising a dual solidification microstructure region, wherein the dual solidification microstructure region comprises (i) one or more fine dendrite portions having a dendrite arm spacing of about 5 to about 30 micrometers, and (ii) one or more fine eutectic portions having a eutectic spacing of 1 micrometer or less.
19. The metal casting of claim 18 further comprising a coarse solidification microstructure region located between the dual solidification microstructure region and a surface of the metal casting.
20. The metal casting of claim 19 further comprising a fine solidification microstructure region located adjacent the dual solidification microstructure region.
21. The metal casting of claim 18, wherein the casting is substantially free of shrinkage porosity.
22. The metal casting of claim 18, wherein the casting is substantially free of damaging iron-rich platelets.
23. A shaped metal casting made in a mold comprising an aggregate, the casting comprising a dual solidification microstructure region, wherein the dual solidification microstructure region comprises at least one coarse.
24 solidification microstructure portion having a dendrite arm spacing in the range of about 50 to about 200 micrometers; and at least one fine solidification microstructure portion having a dendrite arm spacing of less than about 15 micrometers.

24. The metal casting of claim 23, wherein the at least one fine solidification microstructure region is substantially continuous from a distal end of the metal casting to a proximal end thereof.
25. The metal casting of claim 23, wherein the at least one fine solidification microstructure region comprises a first fine solidification microstructure region located adjacent a distal end of the metal casting and a second fine solidification microstructure region located adjacent a proximal end thereof.
26. The metal casting of claim 23, further comprising a substantially continuous fine solidification microstructure region internal to and distinct from the dual solidification microstructure region.
27. The metal casting of claim 24, wherein the at least one fine solidification microstructure portion has a dendrite arm spacing in the range of about 5 to 15 micrometers.
28. The metal casting of claim 23, wherein the casting is substantially free of at least one of (i) shrinkage porosity, and (n) damaging iron-rich platelets.
CA2660940A 2006-08-16 2007-08-14 Solidification microstructure of aggregate molded shaped castings Active CA2660940C (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
US11/505,019 US20080041499A1 (en) 2006-08-16 2006-08-16 Solidification microstructure of aggregate molded shaped castings
US11/505,019 2006-08-16
PCT/US2007/018175 WO2008021450A1 (en) 2006-08-16 2007-08-14 Solidification microstructure of aggregate molded shaped castings

Publications (2)

Publication Number Publication Date
CA2660940A1 true CA2660940A1 (en) 2008-02-21
CA2660940C CA2660940C (en) 2012-07-17

Family

ID=39082327

Family Applications (1)

Application Number Title Priority Date Filing Date
CA2660940A Active CA2660940C (en) 2006-08-16 2007-08-14 Solidification microstructure of aggregate molded shaped castings

Country Status (10)

Country Link
US (2) US20080041499A1 (en)
EP (1) EP2059359B1 (en)
JP (2) JP2010500923A (en)
CN (1) CN101522341B (en)
AU (1) AU2007284439B2 (en)
BR (1) BRPI0716660B1 (en)
CA (1) CA2660940C (en)
GB (1) GB2455007B (en)
MX (1) MX2009001645A (en)
WO (1) WO2008021450A1 (en)

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US9135691B2 (en) * 2012-06-19 2015-09-15 GM Global Technology Operations LLC Metallographic method for accurate measurement of pore sizes and distributions in metal castings
US8622113B1 (en) 2012-09-16 2014-01-07 Charles B. Rau, III Apparatus and method for controlled optimized rapid directional solidification of mold shaped metal castings
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BR112018072004B1 (en) 2016-04-28 2023-05-09 Alotech Limited, Llc PROCESSES FOR MANUFACTURING METAL PRODUCTS AND FOR ENHANCEMENT AND CONTROL MECHANICAL PROPERTIES OF A METAL PRODUCT
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Also Published As

Publication number Publication date
US20150083280A1 (en) 2015-03-26
GB2455007B (en) 2012-02-22
EP2059359A1 (en) 2009-05-20
US20080041499A1 (en) 2008-02-21
GB2455007A (en) 2009-05-27
JP2010500923A (en) 2010-01-14
GB0904243D0 (en) 2009-04-22
JP2014039958A (en) 2014-03-06
MX2009001645A (en) 2009-07-10
AU2007284439B2 (en) 2011-03-10
BRPI0716660B1 (en) 2015-12-15
CN101522341B (en) 2014-10-29
CA2660940C (en) 2012-07-17
CN101522341A (en) 2009-09-02
EP2059359A4 (en) 2012-11-14
BRPI0716660A2 (en) 2015-02-10
AU2007284439A1 (en) 2008-02-21
WO2008021450A1 (en) 2008-02-21
JP5756162B2 (en) 2015-07-29
EP2059359B1 (en) 2014-10-29

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