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WO2016180362A1 - 金属熔体均细化处理的切割破散装置及流变成形方法 - Google Patents

金属熔体均细化处理的切割破散装置及流变成形方法 Download PDF

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Publication number
WO2016180362A1
WO2016180362A1 PCT/CN2016/081982 CN2016081982W WO2016180362A1 WO 2016180362 A1 WO2016180362 A1 WO 2016180362A1 CN 2016081982 W CN2016081982 W CN 2016081982W WO 2016180362 A1 WO2016180362 A1 WO 2016180362A1
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WIPO (PCT)
Prior art keywords
cutting
metal melt
melt
breaking device
metal
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.)
Ceased
Application number
PCT/CN2016/081982
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English (en)
French (fr)
Inventor
刘国钧
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.)
Beijing General Research Institute for Non Ferrous Metals
Original Assignee
Beijing General Research Institute for Non Ferrous Metals
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
Priority claimed from CN201520311108.2U external-priority patent/CN204584206U/zh
Priority claimed from CN201510245587.7A external-priority patent/CN106270420B/zh
Priority claimed from CN201520771948.7U external-priority patent/CN205046175U/zh
Priority claimed from CN201521078338.5U external-priority patent/CN205551420U/zh
Priority claimed from CN201510971278.8A external-priority patent/CN105436436B/zh
Priority claimed from CN201521126795.7U external-priority patent/CN205341841U/zh
Application filed by Beijing General Research Institute for Non Ferrous Metals filed Critical Beijing General Research Institute for Non Ferrous Metals
Publication of WO2016180362A1 publication Critical patent/WO2016180362A1/zh
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D1/00—Treatment of fused masses in the ladle or the supply runners before casting
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D11/00—Continuous casting of metals, i.e. casting in indefinite lengths
    • B22D11/10—Supplying or treating molten metal
    • B22D11/11—Treating the molten metal
    • B22D11/114—Treating the molten metal by using agitating or vibrating means

Definitions

  • the invention relates to a cutting and breaking treatment device for metal melt homogenization and refinement and a flow forming method, in particular to a method for highly dispersing and homogenizing a metal melt and its additives, or a metal half
  • the special device and method for preparing solid slurry belong to the field of metal material thermal processing such as metallurgy and casting.
  • the traditional metal melt processing methods are based on the concept of "stirring", which causes the metal melt to violently tumbling and cause defects in the coiling slag.
  • the high speed rotating cutting piece always induces a large or small disturbance in the melt, and the present invention seeks to improve the metal melt homogenizing cutting blade device to produce a "cutting break" in the metal melt.
  • the effect is also due to the extremely small resistance of the rotary motion, which greatly eliminates the tumbling phenomenon of the molten metal surface and improves the homogenization treatment effect and quality of the metal melt.
  • the present invention has developed a "cutting and breaking" device and method for the metal melt and its composite material.
  • a cutting and breaking device for refining metal melt the device is mainly composed of a cutting piece mechanism, a stirring chamber, a liquid surface protection cover or an upper stop, a coupling, an additive mechanism and a motor;
  • the cutting blade mechanism mainly comprises a rotating shaft and a cutting piece, the cutting piece is mounted on the rotating shaft; the rotating shaft is connected with the motor through a coupling; the cutting piece mechanism is arranged on the shaft of the stirring chamber In the direction, the metal melt is subjected to a cutting and breaking refining treatment; the liquid level protective cover or the upper barrier is disposed above or below the molten metal level in the stirring chamber to prevent liquid level fluctuation and Winding.
  • the rotating shaft is moved up and down by the positive and negative interaction of the motor.
  • the device may further include a moving rail, the motor is mounted on a lifting mechanism that can move up and down, such as a moving rail; the motor can perform one-way (forward or reverse) rotation, or perform positive and negative interaction transformation. Turn.
  • a moving rail the motor is mounted on a lifting mechanism that can move up and down, such as a moving rail; the motor can perform one-way (forward or reverse) rotation, or perform positive and negative interaction transformation. Turn.
  • the apparatus may further include a lifting platform, the stirring chamber being placed on the lifting platform; the motor may perform one-way (forward or reverse) rotation, or perform positive and negative interactive transformation rotation.
  • the rotating shaft can be rotated in the forward or reverse direction in various ways; the cutting blade mechanism can reciprocate up and down in the axial direction with respect to the stirring chamber.
  • the cutting piece is like a knife type, the rotating front end is sharp, the side surface is inclined, horizontal or curved, and the cutting piece A-A cross section may be rectangular, triangular, diamond, round, round, and the like.
  • the cutting pieces may be two or more, and the cutting pieces are arranged on one or several rotating faces.
  • the cutting pieces are two, the shape is a knife shape, the rotating front end is sharp, the lower side is a horizontal plane, the upper side is a sloped surface, and the cutting piece is arranged on one rotating surface, and is circumferentially symmetric along the rotating axis. distributed.
  • the cutting blade can also have a bi-directional sharp rotating front end.
  • the plurality of cutting pieces are arranged in layers on one or several rotating surfaces, between two adjacent cutting pieces (upper cutting piece and lower cutting piece), or left cutting piece and right cutting of the same layer. Between the sheets (on both sides of the rotating shaft), the inclined surfaces of the rotating front end sides are arranged in opposite symmetry with each other.
  • the cutting piece is two layers, and the two-layer cutting piece is rotationally symmetrically distributed along the rotating axis, between the upper cutting piece and the lower cutting piece, or between the lower left cutting piece and the right cutting piece of the lower layer, and the rotating front end thereof
  • the beveled faces of the sides are arranged in opposite symmetry with each other.
  • the rotating front end of the cutting piece is relatively sharp, and the thickness of the rotating front end is ⁇ 5 mm.
  • the cutting pieces are rotationally symmetrically distributed along the axis of rotation.
  • the dicing sheet device can utilize the reciprocal "convection" of the melt itself to suppress the tumbling of the molten metal surface while avoiding the entrainment of the slag.
  • the liquid level protection cover may be a positioning type or a movable buoyancy chamber type, and the middle portion is provided with a narrowing assembly hole, and the assembly hole may be used for connecting the upper and lower melts of the protection cover.
  • the liquid level protection cover is in a flat or inverted "U” shape, and the liquid level protection cover is submerged under the metal liquid surface or fixed on the inner wall of the stirring chamber.
  • the present invention provides a movable buoyancy tank type liquid level protective cover placed in a metal melt container.
  • the utility model is composed of a buoyancy chamber, a vertical plate, a fitting hole and a retaining ring.
  • the vertical plate is vertically connected to one side or both sides of the buoyancy chamber, and an assembly hole is arranged on the buoyancy chamber.
  • the top view shape of the buoyancy chamber is the same as the inner wall contour of the metal melt container, and the gap between the outer edge of the device and the inner wall of the metal melt container is less than 5 mm.
  • the buoyancy chamber is a closed cavity filled with a refractory insulation material.
  • the buoyancy chamber is filled with a refractory insulating material in the middle of the closed cavity, so that the overall density of the device is ⁇ metal melt density, so that the device is automatically suspended on the upper surface of the molten metal.
  • the risers intersect each other to form a grid-like stabilizing structure, while also forming a plurality of closed spaces to prevent disturbances in the melt from being transmitted to adjacent melts.
  • the retaining ring is disposed on the outer circumference of the buoyancy chamber and the fitting hole to further prevent melt disturbance transmission.
  • each riser itself can be designed in a sandwiched configuration to provide the buoyancy required for the device to be suspended.
  • the upper retaining port has a certain thickness or depth, so that the liquid surface of the metal melt is maintained in the upper retaining port; the opening shape of the upper retaining port matches the shape of the cutting blade mechanism, so that the melt is cut.
  • the sheet mechanism is free to enter and exit the stirring chamber in the axial direction.
  • the present invention is improved in terms of the configuration of the melt vessel agitation chamber to prevent the liquid surface from rolling and preventing oxidation when the metal melt is stirred.
  • a stirring chamber for stirring a metal melt is constructed by a melt container, a stirring chamber, an upper stop, an upper blocking rib, a lower blocking rib, a lower bottom, a temperature sensor, and a liquid take-up / pouring gate composition
  • the upper part of the stirring chamber is a narrow upper mouth
  • one end of the upper port is equipped with a temperature sensor
  • the other end is a liquid take-up or pouring port; in addition, the inner wall of the melt vessel above and below the stirring chamber,
  • the upper block ribs and the lower block ribs of the rib-like protrusions are respectively provided, and the lower block ribs are also formed on the lower bottom of the melt container.
  • the metal melt agitation chamber is used in various applications requiring metal melt agitation casting including:
  • the quantitative metal liquid is taken from the liquid intake port of the upper retaining port to keep the liquid surface in the upper retaining port;
  • the sheet mechanism is automatically rotated to a direction matching the shape of the upper opening, and then the cutting blade mechanism and the quantitative length of the refiner filament or the quantitative weight of the refiner scrap are automatically inserted from the upper stopper, and the stirring chamber is placed in the stirring chamber Internally, the metal melt and the fast-melting refiner are strongly homogenized, or the refiner wire itself acts as a cutting blade mechanism for stirring.
  • the stirring temperature drops to the set temperature, the stirring is stopped, from the upper block.
  • the cutting piece mechanism and the remaining additive wire are taken out from the mouth, and then quickly transferred and poured into a spoon for casting.
  • the mobile starter starts to be continuously cast, and continuous liquid supply, continuous supply and continuous stirring are carried out until the end of continuous casting, and the stirring is stopped; finally, the cutting piece mechanism is taken out from the upper stop to realize the casting site at the die casting, continuous casting, etc.
  • the cutting and breaking device further comprises a thermocouple, the thermocouple is disposed in the stirring chamber, and preferably, the thermocouple passes through a fitting hole on the liquid surface protection cover or the upper barrier, or through the liquid surface protection cover Or the gap between the upper stop and the inner wall of the stirring chamber is placed in the metal melt to monitor the temperature of the metal melt in real time.
  • the additive mechanism is disposed above the stirring chamber.
  • the invention can realize the up and down movement of the cutting piece mechanism relative to the stirring cavity by various means, for example, by the forward and reverse interaction of the motor, or the motor moving up and down along the moving rail, or the lifting and lowering of the lifting platform, realizing the rotating axis relative to
  • the metal melt agitating chamber moves up and down, so that the motor can drive the rotating shaft to rotate the cutting piece at a high speed in the stirring chamber while driving them to reciprocate up and down relative to the stirring chamber in the axial direction.
  • a coupling is placed above the molten metal level to quickly connect and separate the motor components, and the melt in the cavity is transferred for casting.
  • the device mechanism is very simple, the model size of the device matches the size of the melt cavity, without any complicated mechanical structure or electromagnetic stirring coil that increases the technical cost.
  • a cutting break and flow forming method for refining a metal melt for homogenizing a metal melt prior to casting comprising the steps of:
  • the preheating additive is added in proportion to the homogenization, and the homogenization treatment of the cutting and breaking is performed; or the preheating additive is continuously added according to the flow rate ratio, and the continuous cutting is simultaneously performed. Disperse homogenization treatment;
  • the cutting blade mechanism reciprocates up and down in the axial direction relative to the stirring chamber while rotating at a high speed in the stirring chamber, by the high-speed rotation of the cutting piece and the up-and-down movement with respect to the stirring chamber, Controllable multi-directional turbulence without liquid level tumbling in the melt, while directly cutting, breaking or dispersing tiny solid phases, second phases, oxides and inclusions in the melt, so that the metal melt before casting All solutes or additives in the interior are highly dispersed and homogenized;
  • the additive is an element or an intermediate alloy such as a refiner, a modifier, an alloy or a composite material
  • the preheating temperature of the additive is 50 ° C to T RL + 50 ° C
  • the T RL is an additive liquid. Phase line temperature.
  • step 2 for continuous casting, the metal melt in the cavity is continuously flowed, the additive is continuously supplied in a flow ratio, and the homogenization treatment of cutting and breaking is also continuous operation; for batch casting (for example, die casting), the cavity Inside is a quantitative metal melt, the additive is "real time" dosing.
  • the stirring chamber is a casting spoon; for continuous casting, the stirring chamber is a hot top above the crystallizer.
  • the rotating shaft when the cutting is broken, can be rotated in one direction, or can be rotated in positive and negative interactions, such as clockwise rotation when rising, counterclockwise rotation when falling, or counterclockwise rotation when rising. Rotate clockwise.
  • the up and down movement of the rotating shaft is realized by the positive and negative alternating transformation of the motor, or the motor moves up and down along the moving rail to move the rotating shaft up and down, or the lifting chamber is moved up and down by the lifting of the lifting platform to realize the rotating shaft and the cutting piece along the shaft. Reciprocating up and down relative to the melt in the agitating chamber.
  • a liquid level protective cover is installed above or below the molten metal level in the stirring chamber, and the liquid level protective cover has a mounting hole for connecting the upper and lower melts of the protective cover.
  • step 4 the casting temperature T is poured : T S ⁇ T poured ⁇ T L + 50 ° C, and T S and T L are metal solid and liquidus temperatures, respectively.
  • a coupling can be used between the motor and the rotating shaft to achieve quick connection and separation between the motor and the rotating shaft; in this case, the coupling needs to be separated to quickly transfer the stirring chamber mechanism (including leaving the coupling) All parts, such as the rotating shaft and the cutting piece, are cast.
  • the flow forming technique can obtain a uniform fine, excellent and compact casting solidification structure.
  • Figure 1 is a schematic view of a cutting and breaking device and a method of using a metal melt.
  • FIG. 2 is a top plan view of the cutting blade mechanism in the stirring chamber.
  • Figure 3-1 to Figure 3-6 are respectively a schematic view of the geometry of the section AA of the cutting piece of Figure 1, wherein Figure 3-1: rectangle; Figure 3-2: right triangle; Figure 3-3: diamond; Figure 3 -4: Square; Figure 3-5: Triangle; Figure 3-6: Round.
  • FIG. 4 is a schematic view showing the structure of a two-layer cutting blade device for homogenizing a metal melt according to the present invention.
  • Figure 5 is a bottom plan view of the two-layer cutting blade device of the metal melt homogenization treatment.
  • Figure 6 is a longitudinal cross-sectional view of the active buoyancy tank type liquid level cover.
  • Fig. 7 is a schematic view showing the shape of the narrowed upper stopper and the inner wall of the stirring chamber.
  • Figure 8 is a top plan view of a metal melt container and a stirring chamber.
  • Figure 9 is a cross-sectional view taken along the line A-A of the metal melt vessel and the stirring chamber of Figure 8.
  • Figure 10 is a cross-sectional view taken along the line B-B of the metal melt vessel and the stirring chamber of Figure 9.
  • Figure 11 is a cross-sectional view taken along line C-C of the metal melt vessel and the stirring chamber of Figure 9.
  • Fig. 12 is a schematic view showing the working process and principle of the metal melt cutting and breaking treatment method.
  • the present invention provides a cutting and breaking device and method for metal melt homogenization treatment, and the present invention will be further described below in conjunction with the accompanying drawings and specific embodiments.
  • FIG. 1 it is a schematic diagram of the main structure and use method of the device of the present invention.
  • the device mainly comprises a cutting blade mechanism, a stirring chamber 8 , a liquid level protective cover 3 or an upper blocking port 24 , a coupling 4 , a thermocouple 5 ,
  • the motor 6, the wire feeding mechanism 41 (or called an additive mechanism), and the lifting mechanism such as the moving rail 7 are composed of several parts.
  • the cutting blade mechanism mainly comprises a cutting piece 1 and a rotating shaft 2, and the cutting piece 1 is arranged and mounted on the rotating shaft 2, and the rotating shaft 2 and the motor 6 are connected by a coupling 4, that is, one end of the coupling 4 and the rotating shaft 2 Connected, the other end is connected to the motor 6, the motor 6 is mounted on the movable rail 7 which can be moved up and down, and can move up and down along the moving rail 7, and the cutting piece 1 and the rotating shaft 2 are disposed in the stirring chamber 8 of the metal melt. In the axial direction, the cutting blade mechanism can be moved up and down. When the metal melt is processed, it descends into the stirring chamber 8; when the work is completed, it rises out of the stirring chamber 8.
  • the liquid level protective cover 3 or the upper retaining port 24 is placed under the metal level 10 in the stirring chamber 8, and the liquid level protective cover 3 is provided with a mounting hole 9 for connecting the upper and lower metal melting of the liquid level protective cover 3.
  • the thermocouple 5 is placed in the metal melt through the fitting hole 9 or the gap between the liquid level shield 3 and the inner wall of the stirring chamber 8 for measuring the temperature of the metal melt.
  • the motor 6 component can be moved up and down along the moving rail 7, so that the motor 6 can drive the upper and lower reciprocating motions while driving the rotating shaft 2 to rotate at a high speed, and the rotating shaft 2 can drive the cutting blade 1 in the stirring chamber 8. It can also reciprocate up and down in the axial direction while rotating at high speed.
  • a coupling 4 can be added to quickly connect and separate the components of the motor 6, transferring the melt in the agitating chamber 8 for casting.
  • the function of the coupling 4 is to achieve a quick connection or separation of the device configuration with the output shaft of the rotating electrical machine.
  • the vertical movement of the rotating shaft 2 relative to the stirring chamber 8 can be realized directly by the forward and reverse interaction of the motor 6, or the lifting chamber 8 can be placed on the lifting platform by using a lifting platform.
  • the up-and-down reciprocating movement of the stirring chamber 8 relative to the rotating shaft 2 is realized by the lifting and lowering of the lifting platform, so that the motor 6 can also drive the rotating shaft 2 to rotate the cutting piece 1 at a high speed in the stirring chamber 8 while driving them in the axial direction. Reciprocating up and down in the stirring chamber 8.
  • the cutting piece 1 resembles a knife type (see A-A direction): its rotating front end is sharp (or tapered), and the side surface is beveled, horizontal or curved.
  • the rotary shaft 2 is required to perform forward and reverse cross-change rotation
  • the used cutting blade 1 has a bidirectional sharp rotary front end as shown in Figs.
  • the rotary shaft 2 performs forward and reverse cross-change rotation, for example, clockwise rotation when rising, counterclockwise rotation when descending, or counterclockwise rotation when rising, and clockwise rotation when falling.
  • the cross section of the cutting piece A-A may be a rectangle, a triangle, a diamond, a circle, or the like, as shown in FIGS. 3-1 to 3-6.
  • a plurality of cutting sheets 1 are arranged on one or several rotating faces.
  • the dicing sheet of the present invention may be layered on one or several rotating faces, between two adjacent dicing sheets (upper dicing sheet and lower dicing sheet), or the same layer of left and right dicing sheets (located Between the two sides of the rotating shaft, the direction of the slope of the side of the rotating front end may be arranged in reverse symmetry with each other.
  • the upper cutting blade 11 is mounted at the upper middle position of the rotary shaft 2
  • the lower cutting blade is mounted at the lower position of the rotary shaft 2
  • the rotary shaft 2 is coupled to the coupling 4
  • the upper cutting blade 11 is
  • the left cutting piece 12 of the lower cutting piece, the right cutting piece 13 of the lower cutting piece, the liquid level protective cover 3 and the rotating shaft 2 are both placed in the stirring chamber 8 of the metal melt, the upper cutting piece 11 and the left cutting of the lower cutting piece
  • the sheet 12 and the right cutting piece 13 of the lower cutting piece are both knife-shaped, and the side of the rotating front end is a sloped surface.
  • the model size of the dicing sheet device of the present invention matches the size of the melt agitation chamber 8.
  • the rotating front end of the cutting piece is relatively sharp, the thickness of the rotating front end is ⁇ 5 mm, and the side surface is flat, inclined or curved.
  • the cutting piece has a sharp or narrow rotating front end, which can fully exert the function of “cutting and breaking” when rotating at high speed in the metal melt, and the high-strength shear force generated directly cuts and breaks all the melt.
  • the tiny solid phase, the second phase, the oxide, the inclusions and even the molecules are arranged in an orderly manner, and the rotational motion resistance of the geometric structure is extremely small, which can greatly reduce the liquid surface tumbling phenomenon.
  • the upper and lower sides of the cutting piece may be flat (no bevel or curved surface).
  • the two-layer cutting piece of the invention is rotationally symmetrically distributed along the rotation axis, and the slope direction of the side surface of the cutting piece is It is desirable to design between the layers or between the left and right portions in the same layer to be arranged in opposite symmetry with each other. That is to say: the upper cutting piece 11 (see FIG. 4A-A direction, the direction of the inclined side of the rotating front end side is downward) and the lower cutting piece (see FIG. 4B-B direction, the direction of the inclined side of the rotating front end is upward), The left cutting piece 12 of the lower cutting piece (see FIG. 4C-C direction, the direction of the inclined side of the rotating front end side is downward) and the right cutting piece 13 (see FIG. 4B-B direction, the direction of the inclined side of the rotating front end side is upward) They can be arranged in reverse symmetry with each other as needed.
  • the slope direction of the rotating front end side of the lower cutting piece is upward (BB direction), and at the high speed rotation, a pushing force against the molten metal is generated; and the inclined direction of the rotating front end side of the upper cutting piece 11 is downward. (AA direction), while generating another downward force on the molten metal.
  • the dicing sheet device of the present invention can utilize the reciprocal "convection" of the melt itself to suppress the metal surface tumbling and avoid the slag slag, and can be widely applied to continuous casting, while efficiently cutting and processing the metal melt as a whole.
  • Various metal casting occasions such as die casting, forging casting, and batch molding.
  • the liquid level cover 3 is provided with a fitting hole 9 which can be used to connect the upper and lower melts of the protective cover.
  • the function of the liquid level cover 3 is to further protect the metal level and completely eliminate the liquid level tumbling.
  • the liquid level cover 3 may be in a flat or inverted "U" shape and immersed under the molten metal surface.
  • the liquid level cover 3 can also be fixedly mounted on the inner wall of the stirring chamber 8.
  • the liquid level protection cover may be a positioning type (see FIG. 1), or a movable buoyancy chamber type (see FIG. 6), and a narrowed assembly hole 9 in the middle.
  • a movable buoyancy tank type liquid level cover is placed in the melt container, which is composed of a buoyancy chamber 21, a vertical plate 22, a fitting hole 9, and a retaining ring 23.
  • the vertical plate 22 is vertically connected to one side or both sides of the buoyancy chamber 21, and an assembly hole 9 is provided in the buoyancy chamber 21.
  • the shape of the buoyancy chamber 21 is the same as the contour of the inner wall of the melt container.
  • the shape of the fitting hole 9 in the buoyancy chamber 21 will depend on the shape of the melt cutting blade mechanism, so that the cutting blade mechanism can be lowered into and out of the stirring chamber 8 during operation.
  • the shape of the fitting hole is also a rectangular shape of a suitable size.
  • an aluminum alloy melt that needs to be homogenized is protected by an active buoyancy tank type liquid level cover: the vertical plate 22 is disposed on the upper and lower sides of the buoyancy chamber 21, and the buoyancy chamber 21 is welded into a hollow form by a titanium alloy sheet. It is made of lightweight aluminum silicate heat-resistant insulation material.
  • the buoyancy chamber type liquid level cover is automatically suspended on the upper surface of the aluminum alloy liquid, and the blade-shaped melt homogenization agitation shearing mechanism is inserted from above.
  • the aluminum liquid in the container is subjected to homogenization treatment at a high speed.
  • the shear agitation of the blade causes agitation disturbance of the aluminum alloy melt in the lower part of the isolator, the isolator can still isolate the rotational torque from the lower main melt, which is good for stabilizing the upper melt level. The effect is to keep the metal level still.
  • the blade-type shear agitating mechanism lifts the aluminum liquid from the assembly hole, and then rapidly transfers the melt of the container for casting.
  • the upper retaining opening 24 of the present invention has a certain thickness or depth to maintain the liquid level of the molten metal in the upper retaining opening 24; the opening shape of the upper retaining opening 24 is shaped as the shape of the cutting blade mechanism. The matching allows the melt cutting blade mechanism to freely enter and exit the agitating chamber 8 in the axial direction.
  • the metal melt container and the stirring chamber of the present invention can adopt the structure shown in Figs. 8 to 11 .
  • the configuration of the stirring chamber shown in the drawing is composed of a melt container 31, a stirring chamber 8, an upper port 24, an upper blocking rib 32, a lower blocking rib 33, a lower bottom 34, a thermocouple 5, and a liquid take-up.
  • the inner wall of the melt container 31 is provided with upper rib ribs 32 and lower ribs 33, respectively, and rib ribs 33 are also formed on the lower bottom 34 of the melt container.
  • the upper portion of the agitation chamber 8 is a narrowed upper port 24 configuration to prevent agitating vortex and gas from being generated in the melt level.
  • the narrowed upper stop 24 configuration changes the flow field distribution of the melt in the agitating chamber 8, and blocks the transfer path of the agitating flow to the upper level.
  • the narrowed upper retaining port 24 has a certain thickness or depth to maintain the liquid level of the molten metal in the upper retaining port 24, achieving a "wider agitating cavity melt" relative to a "narrow liquid level”.
  • Others use "liquid level protective cover” devices because they are thinner and do not "narrow the liquid level”.
  • the shape of the opening of the upper retaining port 24 matches the shape of the cutting blade mechanism, so that the melt cutting blade mechanism can freely enter and exit the stirring chamber 8, and is narrowed as much as possible to achieve the best barrier stirring effect.
  • a thermocouple 5 is attached to one end of the narrowed upper port 24, and the other end is a liquid take-up or pouring port 35.
  • upper and lower retarding ribs are respectively disposed on the inner wall of the melt container 31 above and below the stirring chamber 8 to further block the vicinity of the liquid surface. The vortex increases the agitation shear force, resulting in a better melt homogenization treatment.
  • the metal melt stirring chamber is used in various occasions where metal melt agitation casting is required: in the case of intermittent casting such as die casting, the stirring chamber structure is the inner cavity structure of the pouring spoon (only for the existing pouring spoon) Add a live block as shown in the dotted line in Figure 9.)
  • a certain amount of metal liquid is first taken from the liquid take-up port of the upper port 24 to keep the liquid level in the upper port 24. Automatically rotating the cutting blade mechanism to a direction matching the shape of the upper opening opening, and then automatically inserting the cutting blade mechanism and the quantitative length of the refiner filament (or the quantitative weight of the refiner debris) from the upper stop,
  • the metal melt and the refining agent which is rapidly melting are subjected to intense homogenization agitation in the agitation chamber 8.
  • the refiner wire itself can also be rotated at a high speed to become a cutting blade mechanism.
  • a uniform melt release is carried out while stirring in the melt.
  • the stirring temperature is lowered to a set temperature, the stirring is stopped, the cutting blade mechanism is taken out from the upper stopper, and then the pouring spoon is quickly transferred and poured to perform casting.
  • the stirring chamber is the inner cavity structure of the hot section of the melt, and the stirring chamber 8 can be directly docked with the continuous casting mold without the bottom bottom; for the electromagnetic stirring without the agitator, the upper blocking port 24
  • the shape of the opening may be a narrowed circle or square.
  • the ingot starts to be continuously cast, and continuous continuous liquid supply, continuous supply of silk and continuous stirring are continued until the continuous casting process is finished, and the stirring is stopped. Finally, the cutting blade mechanism is withdrawn from the upper port 24. Achieve full automation of the melt agitation process at the casting site—chemical refinement—the entire process of casting.
  • a method for cutting and breaking a metal melt and a flow forming method using the apparatus of the present invention can be used for homogenizing a metal melt before casting, including the following steps:
  • Step 1-2 is shown in Figure 12.
  • the stirring chamber 8 is a casting spoon; for continuous casting, the stirring chamber 8 is a hot top above the crystallizer.
  • the cutting blade mechanism reciprocates up and down in the axial direction relative to the stirring chamber 8 while rotating at a high speed in the stirring chamber 8 at high speed (the motor 6 moves up and down along the moving rail 7).
  • the rotating shaft 2 moves up and down, or the vertical movement of the rotating shaft 2 is realized by the forward and reverse rotation of the motor 6, or the stirring chamber 8 is moved up and down by the lifting of the lifting table, or other moving manners, as shown in step 2 of FIG.
  • the lower (or upper) vicinity of the molten metal surface in the stirring chamber 8 is provided with the liquid level protective cover 3, the liquid level protective cover 3 or the upper opening
  • the phase, the second phase, the oxide and the inclusions provide a high degree of uniform dispersion of the solute in the molten metal prior to solidification.
  • the "cutting and breaking" treatment method of the melt is different from the previous "stirring" concept, which is like the difference between "agitator” and “soybean machine".
  • the mixing chamber 8 is a quantitative metal melt
  • the additive R is "real-time" dosing
  • the melt treatment is a few seconds or the cutting is broken to the melt temperature to reach the casting Temperature T pouring :
  • T S ⁇ T is poured ⁇ T L +50 °C
  • T S and T L are respectively metal solidus and liquidus temperature
  • the homogenization treatment of cutting and breaking is stopped, and the cutting blade mechanism is lifted out.
  • Surface or separate coupling
  • the homogenization treatment of the metal melt cutting and breaking is continuous operation in the hot top, the metal melt in the stirring chamber 8 is continuously flowed, and the addition of the additive R is continuously supplied according to the flow rate ratio, and the cutting is broken.
  • the homogenization process is also continuous operation; until the end of the continuous casting process, the cutting blade mechanism stops and rises out of the hot top, completing step 3 as shown in FIG.
  • the purpose of this flow forming technique is to obtain a uniform fine, fine and dense solidification structure of the casting.
  • the following is an application example of real-time homogenization treatment of AZ91 magnesium alloy and rheological die-casting automobile connecting rod by cutting and breaking device of metal melt and flow forming method.
  • the cutting piece device adopts three cutting pieces 1 (the shape is as shown in Fig. 2, the cutting piece is like a knife type (see AA direction), the rotating front end is sharp, the lower side is a horizontal plane, the upper side is a bevel), three rotating surfaces, and the circumferential direction. Symmetrical structural arrangement.
  • 1. Firstly refine the refiner element C (1wt.% of Mg-Al-C master alloy) required for AZ91 magnesium alloy to 660 ° C under protective atmosphere (645 ° C is in the middle of Mg-Al-C) The liquidus temperature of the alloy). 2.
  • the rotating shaft can drive the cutting piece to reciprocate up and down in the axial direction while rotating at a high speed in the stirring chamber.
  • This geometric design and working mode makes the disturbance experienced by the molten metal in the cavity "controllable in range and strength" and is a multi-directional turbulent flow in the centrifugal radial direction, the rotating circumferential direction and the upper and lower axial directions.
  • the controllable turbulence is further equipped with a liquid level protective cover, which can homogenize the metal melt as a whole, and avoid the drawbacks of the coiling slag caused by other inventions being "stirring and tumbling".
  • the high-strength shearing action of the sharp cutting piece directly cuts and breaks all the tiny solid phases, the second phase, the oxide, the inclusions and even the molecular order in the melt, so that the solute in the molten metal before casting is highly dispersed. Homogenization, obtaining a fine, fine and dense casting structure after rapid solidification. Therefore, this method of cutting and breaking is to create a "controllable turbulent flow" while having a “cutting and breaking” effect.
  • the invention is simple and efficient, and also introduces a special refiner preheating and real time before casting. Added method.
  • the cutting piece device of the invention can greatly inhibit the metal liquid surface tumbling while avoiding the coiling of the slag in the overall high efficiency cutting and processing of the metal melt, and can be widely applied in continuous casting, die casting, forging casting, die casting and compounding in real time.
  • Various metal casting occasions such as material preparation.
  • the conventional isolator device is fixedly mounted at a certain position in the container, and the buoyant chamber liquid level cover of the present invention is designed to stably suspend the device near the melt level by adjusting the overall density of the device material, and it can automatically Move up and down following the change in the level of the melt.
  • the invention adopts a buoyancy tank structure like a "ship": the upper buoyancy chamber is made into a closed cavity for adjusting the average density of the entire isolator device, so that the device can be automatically suspended on the upper surface of the molten metal; the buoyancy chamber The intermediate cavity is filled with lightweight refractory insulation to remove internal air and prevent the device from expanding when heated.
  • the overall density of the adjustment device as a whole is ⁇ metal melt density, so that the isolator device can be automatically suspended near the liquid surface of the metal melt during use.
  • the buoyant tank liquid level protection cover of the invention can isolate the liquid surface portion of the upper part of the large volume melt from the main melt of the lower part, effectively blocking the disturbance of the main melt when subjected to vigorous stirring, and transmitting to the upper liquid level, thereby When the large disturbance occurs in the melt, the liquid level is still calm, and the purpose of stabilizing the melt level is achieved, and at the same time, the oxidation of the melt, the slag and the gas are prevented from being contaminated.
  • the stirring cavity for stirring the metal melt of the invention can narrow the melt liquid surface in the stirring chamber, thereby effectively blocking the effect of the stirring effect on the liquid surface, and solving the problem of the oxidation and the gas volume risk of the melt.
  • the "narrow liquid level" structure reduces the tendency of the melt to oxidize and inhale, and also blocks the transfer of the agitated flow field to the liquid surface, so that the molten metal melt surface is free of turbulence and vortex, avoiding melt oxidation. , gas, slag.
  • the device achieves the purpose of feeding the refiner wire in real time and automatically in the pouring spoon.
  • continuous “feeding” is a real-time method of adding refiners.
  • the addition of elements such as refiner is generally carried out in advance in the smelting holding furnace. Due to the large amount and the slow casting cycle, the batch is successively taken out of the molten metal. The element content is not uniform, segregation, and even the refiner effect is degraded.
  • the idea of the invention is: firstly, after the preliminary premixing of the elements such as the refining agent in the large smelting holding furnace, the elements which are quantitatively taken out and the molten material to be cast are again subjected to the "real time" refining agent and the like are added. It can fully guarantee the content of each element of the batch is equal, and can prevent the decline of elemental efficiency to the greatest extent.
  • the method and apparatus for "melting and breaking" of the metal melt homogenization treatment are the main creations of the present invention.
  • the cutting blade device designed by the invention has a knife-like shape: the rotating front end is sharp, and the high-strength shearing action can directly cut and break all the tiny solid phases, the second phase, the oxide, the inclusions and even the molecular order in the melt; If the front end of the cutting piece is a tapered design, it can be used to disperse and mix the metal matrix composite; the side of the cutting piece is inclined, horizontal or curved, and the "stirring” effect can be adjusted according to the adjustment of different slope and curvature: slope The greater the curvature, the more intense the "stirring” effect; if the slope is very close to the horizontal plane, the circumferential flow is close to the laminar flow.
  • the "cutting and breaking” device and method make the disturbance experienced by the metal melt in the cavity "controllable in range and intensity", local ordered laminar flow but overall turbulence
  • the rotating shaft can drive the cutting piece to reciprocate in the axial direction while rotating at high speed in the stirring chamber, and the locally ordered controlled flow can be applied to the entire melt without the liquid surface tumbling. Therefore, the cutting and breaking device and method have the effect of "cutting and breaking" while manufacturing "controllable turbulence".
  • the invention is simple and efficient, and achieves important innovations in the principles of metal melt processing and casting.
  • the structure is simple, easy to use, and the treatment effect is high quality and high efficiency.
  • the “cutting and breaking” mechanism realizes the uniform and strong shear homogenization treatment of the melt.

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Abstract

一种金属熔体均细化处理的切割破散装置，包括切割片机构、搅拌腔(8)、液面保护罩(3)或上挡口(24)、联轴器(4)、添加剂机构(41)和电机(6)；设置在搅拌腔(8)轴向上的切割片机构包括切割片(1)和旋转轴(2)，切割片(1)安装在旋转轴(2)上；旋转轴(2)与电机(6)通过联轴器(4)连接；液面保护罩(3)或上挡口(24)设置于搅拌腔(8)内熔体液面(10)的上方或下方。切割片(1)为刀型，旋转前端锐利，侧面呈斜面、水平面或曲面。该装置还可包括移动轨(7)或升降台。旋转轴在带动切割片在搅拌腔内高速旋转的同时还能沿轴向上下往复运动，在制造"可控紊流"的同时兼有"切割破散"效应，使熔体内所有溶质高度弥散均匀化，进而获得均匀细小、优良致密的铸件凝固组织。还公开了一种金属熔体均细化处理的切割破散与流变成形方法。

Description

金属熔体均细化处理的切割破散装置及流变成形方法 技术领域
本发明涉及一种金属熔体均匀化和细化的切割破散处理装置及流变成形方法，特别涉及一种用于金属熔体及其添加物的高度分散、均匀化处理，或金属半固态浆料制备的特殊装置与方法，属于冶金、铸造等金属材料热加工领域。
背景技术
在冶金、铸造等金属材料热加工领域中，人们已经对金属熔体施加了各种“搅拌”处理(例如半固态金属浆料或复合材料制备、电磁搅拌、机械搅拌等)，为的是熔体能在一定尺度上的温度和成分均匀化，从而增加凝固过程中的有效形核数量、削减结晶界面前沿的成分过冷现象、使晶体发达的迅速长大受到抑制，结晶成为细小的等轴晶组织。虽然目前关于金属搅拌凝固的机制有上述“结晶抑制”理论和其它如“枝晶折断”理论等多种解释，但多数人认为，通常的“搅拌”力度无法达到折断枝晶的程度，熔体内的微小固相、氧化皮等物质只能在搅拌时发生“折叠”或“熔断”。那么，能否发明一种易行的装置和方法，能有效促进合金各组份溶解或相的均质化，并共同借助“抑制”和“折断”两种基体结晶机制来高效、优质地进行铸造熔体的均匀化处理呢？这就是本发明的“切割破散”装置和方法所要解决的问题。
传统的金属熔体处理方法都是基于“搅拌”的理念，这就使得金属熔体剧烈翻腾而引起卷气卷渣缺陷。高速旋转的切割片总会在熔体内引发或大或小的扰动，本发明试图改进金属熔体均匀化处理的切割片装置，使其能在金属熔体中产生一种“切割破散”效应，还由于其旋转运动阻力极小，极大消除了金属液面的翻腾现象，提高金属熔体的均匀化处理效果和品质。
发明内容
为了发挥多种机制优势，实现简单高效、优质无害地均匀化处理金属熔体的要求，本发明研制了金属熔体及其复合材料的“切割破散”装置与方法。
一种金属熔体均细化处理的切割破散装置，该装置主要由切割片机构、搅拌腔、液面保护罩或上挡口、联轴器、添加剂机构以及电机等几部分组成；所述的切割片机构主要包括旋转轴和切割片，所述的切割片安装在旋转轴上；所述的旋转轴与电机之间通过联轴器连接；所述的切割片机构设置在搅拌腔的轴向方向上，对金属熔体进行切割破散的均细化处理；所述的液面保护罩或上挡口设置于搅拌腔内金属熔体液面附近的上方或下方，防止液面波动和卷气。
该装置中，通过电机的正、反转交互变换，使旋转轴实现上下往复移动。
该装置还可包括移动轨，所述的电机安装在可上、下移动的升降机构，如移动轨上；电机可进行单向(正向或反向)转动，或者进行正、反向交互变换转动。
该装置还可包括升降台，所述的搅拌腔置于升降台上；电机可进行单向(正向或反向)转动，或者进行正、反向交互变换转动。
通过多种方式，旋转轴可以进行正向或反向旋转；切割片机构可以相对于搅拌腔沿轴向上下往复运动。
所述的切割片似刀型，旋转前端锐利，侧面呈斜面、水平面或曲面，切割片A-A向截面可以为矩形、三角形、菱形、圆形、类圆形等。
所述的切割片可为2个或以上，所述的切割片布置在一个或数个旋转面上。
优选的，所述的切割片为2个，形状为刀型，旋转前端锋利，下侧面是水平面，上侧面是斜面，所述的切割片布置在1个旋转面上，沿旋转轴周向对称分布。切割片还可具有双向的尖锐旋转前端。
所述的切割片为复数个，在一个或数个旋转面上分层布置，相邻两层的切割片(上层切割片和下层切割片)之间，或者同一层的左切割片和右切割片(位于旋转轴两侧)之间，其旋转前端侧面的斜面方向相互呈反向对称布置。
优选的，所述的切割片为二层，二层切割片沿旋转轴呈旋转对称分布，上层切割片和下层切割片之间，或者下层的左切割片和右切割片之间，其旋转前端侧面的斜面方向相互呈反向对称布置。
优选的，所述切割片旋转前端相对锐利，旋转前端的厚度≤5mm。
优选的，切割片沿旋转轴呈旋转对称分布。
该切割片装置在整体切割处理金属熔体的同时，可利用熔体自身的互逆“对流”来抑制金属液面翻腾而避免卷气卷渣。
所述的液面保护罩可以是定位式、或活动的浮力舱式，中部设有收窄的装配孔，装配孔可用于联通保护罩上部和下部熔体。
优选的，所述液面保护罩呈平面或倒“U”形，液面保护罩浸没在金属液面下，或固定在搅拌腔内壁上。
为了解决熔融熔体在受到搅动时，液面剧烈起伏而带来的熔体氧化和卷气卷渣问题，本发明提供了一种活动的浮力舱式液面保护罩，放置于金属熔体容器内，由浮力舱、立板、装配孔和挡圈组成，立板垂直连接在浮力舱的一侧或两侧，并在浮力舱上设置有装配孔。所述浮力舱的俯视图形状与金属熔体容器的内壁轮廓相同，所述装置的外缘与金属熔体容器内壁的间隙小于5mm。
进一步地，所述浮力舱为密闭空腔，中间填充耐火保温材料。
所述浮力舱密闭空腔中间填充耐火保温材料，使装置整体的平均密度≤金属熔体密度，从而使装置自动悬浮于金属液面上部。
进一步地，所述立板相互交叉形成网格状稳定结构，同时也形成了许多闭合空间，以防止熔体中的扰动对流向相邻熔体传递。所述挡圈设置在浮力舱及装配孔的外周，以进一步防止熔体扰动传递。
在省略浮力舱的情况下，可以将每块立板自身设计成中部有夹层的构造，以提供装置悬浮所需的浮力。
本发明中，所述的上挡口具有一定的厚度或深度，能使金属熔体的液面保持在上挡口内；上挡口的开口形状与切割片机构的形状相匹配，使熔体切割片机构能沿轴向自由进出搅拌腔。
同时，本发明从熔体容具搅拌腔室构造方面进行改进，以达到搅拌金属熔体时防止液面翻卷和防氧化的作用。
一种用于搅拌金属熔体的搅拌腔，搅拌腔的构造是由熔体容具、搅拌腔、上挡口、上阻滞凸棱、下阻滞凸棱、下底、温度传感器和取液/浇注口组成，搅拌腔的上方是收窄的上挡口，上挡口的一端安装温度传感器，另一端为取液或浇注口；此外，在搅拌腔上方和下方的熔体容具内壁，分别设置筋条状凸起的上阻滞凸棱、下阻滞凸棱，在熔体容具的下底上也有下阻滞凸棱。
所述金属熔体搅拌腔在各种需要进行金属熔体搅拌铸造场合的应用包括：
1)用于间歇式铸造场合时，它成为浇注汤勺的内腔构造，使用时，首先从上挡口的取液口舀取定量的金属液体，使液面保持在上挡口内；将切割片机构自动旋转至与上挡口开口形状相匹配的方向，然后从上挡口自动插入切割片机构和定量长度的细化剂细丝或投入定量重量的细化剂碎屑，并在搅拌腔内对金属熔体和快速熔化的细化剂实施强烈的均匀化搅拌，或以细化剂丝材自身充当切割片机构进行搅拌，当搅拌温度降到设定温度时，停止搅拌，从上挡口抽出切割片机构和剩余的添加剂丝材，然后迅速转移、倾转汤勺进行浇铸。
2)用于连续铸造时，它是结晶器上方热顶的内腔构造，无需下底，直接将搅拌腔与连铸结晶器对接；使用时，金属熔体从上挡口的取液口流入搅拌腔，并使液面稳定保持在上挡口内；当熔体温度达到设定的搅拌温度时，从上挡口自动插入切割片机构和细化剂细丝，在搅拌腔内对金属熔体实施强烈搅拌，或以细化剂丝材自身充当切割片机构进行搅拌。同时，移动引锭开始连续铸造，并进行连续供液、连续供丝和连续搅拌直至连铸结束，停止搅拌；最后从上挡口抽出切割片机构，实现了在压铸、连铸等铸造现场的熔体搅拌处理—化学细化—浇铸整个过程的全自动 化。
所述的切割破散装置还包括热电偶，所述的热电偶设置于搅拌腔内，优先的，所述的热电偶通过液面保护罩或上挡口上的装配孔，或者通过液面保护罩或上挡口与搅拌腔内壁的间隙置于金属熔体中，对金属熔体温度进行实时监控。
所述的切割破散装置中，所述的添加剂机构设置于搅拌腔的上方。
本发明可通过多种方式实现切割片机构相对于搅拌腔的上下运动，例如：通过电机的正反转交互变换，或者电机沿移动轨上下移动，或者升降台的升降，实现了旋转轴相对于金属熔体搅拌腔的上下往复移动，这样，电机就能在驱动旋转轴带动切割片在搅拌腔内高速旋转的同时还带动它们沿轴向相对于搅拌腔上下往复运动。在旋转轴位于金属熔体液面上方处，设置一个联轴器，以快速连接和分开电机部件，转移容腔内的熔体进行铸造。
该装置机构非常简单，装置的型号尺寸与熔体容腔的尺寸相匹配，无任何增加技术成本的复杂机械结构或是电磁搅拌线圈。
一种金属熔体均细化处理的切割破散与流变成形方法，用于在铸造前均匀化处理金属熔体，包括如下步骤：
①先将金属熔体所需的添加剂预热；
②在处于搅拌腔内即将铸造的金属熔体中，实时按比例加入预热的添加剂后，进行切割破散的均匀化处理；或者按流量比例连续加入预热的添加剂，同时进行连续地切割破散的均匀化处理；
③熔体进行切割破散处理时，切割片机构在搅拌腔内高速旋转的同时还沿轴向相对于搅拌腔进行上下往复运动，通过切割片的高速旋转和相对于搅拌腔的上下移动，在熔体内形成无液面翻腾的可控多向紊流，同时还直接切割、破散或分散熔体内的微小固相、第二相、氧化物和夹杂物等，使铸造前金属熔体内的所有溶质或添加剂高度弥散均匀化；
④对于压铸等间歇式铸造，熔体处理数秒或在金属熔体温度降低达到浇铸温度(T浇)时，停止切割破散的均匀化处理，将切割片机构升出液面(或分开联轴器)，迅速转移搅拌腔(汤勺)，并浇铸已高度均质化的金属熔体(T浇≥TL)或半固态浆料(TS＜T浇＜TL)；对于连续铸造，金属熔体切割破散的均匀化处理是在热顶内连续运行，直至连铸过程结束后，切割片机构停转并升出热顶，从而获得均匀细小、优良致密的铸件凝固组织。
步骤①中，所述的添加剂为细化剂、变质剂、合金或复合材料颗粒等元素或中间合金，所述添加剂的预热温度为50℃～TRL+50℃，TRL为添加剂的液相线温度。
步骤②中，对于连续铸造，容腔内的金属熔体是连续流过，添加剂是按流量比例连续供给，切割破散的均匀化处理也是连续运行；对于间歇铸造(例如模铸)，容腔内是定量的金属熔体，添加剂是“实时的”定量加入。
对于压铸等间歇式铸造情形，所述搅拌腔就是浇铸汤勺；对于连续铸造情形，所述搅拌腔就是结晶器上方热顶。
步骤③中，进行切割破散时，旋转轴可进行单向旋转，或者可进行正、反向交互变换旋转，如上升时顺时针旋转，下降时逆时针旋转，或上升时逆时针旋转，下降时顺时针旋转。
通过电机的正、反转交互变换实现旋转轴的上下移动，或者电机沿移动轨上下移动带动旋转轴上下移动，或者通过升降台的升降带动搅拌腔上下移动，来实现旋转轴和切割片沿轴向相对于搅拌腔内熔体的上下往复运动。
在搅拌腔内金属熔体液面附近的上方或下方安装液面保护罩，液面保护罩上有装配孔，可联通保护罩上部和下部熔体。
步骤④中，浇铸温度T浇：TS＜T浇＜TL+50℃，TS、TL分别为金属固、液相线温度。电机和旋转轴之间可以采用联轴器连接，以实现电机与旋转轴的快速连接和分开；在此情况下则需分开联轴器，迅速转移搅拌腔机构(包含脱离联轴器后留下的旋转轴和切割片等所有部件)进行浇铸。
本流变成形技术可以获得均匀细小、优良致密的铸件凝固组织。
附图说明
图1为金属熔体的切割破散装置与使用方法示意图。
图2为搅拌腔内切割片机构的俯视示意图。
图3-1至图3-6分别为图1中切割片A-A向截面的几何形状示意图，其中，图3-1：矩形；图3-2：直角三角形；图3-3：菱形；图3-4：正方形；图3-5：三角形；图3-6：类圆形。
图4为本发明金属熔体均匀化处理的二层切割片装置的结构示意图。
图5为本金属熔体均匀化处理的二层切割片装置的仰视平面图。
图6为活动的浮力舱式液面保护罩纵截面示意图。
图7为收窄的上挡口及搅拌腔内壁形状示意图。
图8为金属熔体容具和搅拌腔的俯视图。
图9为图8中金属熔体容具和搅拌腔的A-A向剖视图。
图10为图9中金属熔体容具和搅拌腔的B-B向剖视图。
图11为图9中金属熔体容具和搅拌腔的C-C向剖视图。
图12为金属熔体切割破散处理方法的工作过程和原理示意图。
主要附图标记说明：
1     切割片                     2     旋转轴
3     液面保护罩                 4     联轴器
5     热电偶                     6     电机
7     移动轨                     8     搅拌腔
9     装配孔                     10    液面
11    上层切割片                 12    下层切割片的左切割片
13    下层切割片的右切割片
21    浮力舱                     22    立板
23    挡圈                       24    上挡口
31    熔体容具                   32    上阻滞凸棱
33    下阻滞凸棱                 34    下底
35    取液/浇注口
41    喂丝机构                   42    添加剂丝材
具体实施方式
本发明提供了一种金属熔体均匀化处理的切割破散装置与方法，下面结合附图和具体实施方式对本发明作进一步说明。
如图1所示，是本发明装置的主要构造和使用方法示意图，该装置主要由切割片机构、搅拌腔8、液面保护罩3或上挡口24、联轴器4、热电偶5、电机6、喂丝机构41(或称为添加剂机构)、升降机构如移动轨7等几部分组成。切割片机构主要包括切割片1和旋转轴2、切割片1布置安装在旋转轴2上，旋转轴2与电机6之间通过联轴器4相连接，即联轴器4一端与旋转轴2连接，另一端与电机6连接，电机6安装在可上、下移动的移动轨7上，并可沿移动轨7上下移动，切割片1和旋转轴2设置于金属熔体的搅拌腔8的轴向方向上，切割片机构可上下移动，当处理金属熔体时，它下降进入搅拌腔8；当工作完成后，它升出了搅拌腔8。液面保护罩3或上挡口24置于搅拌腔8内的金属液面10下方，液面保护罩3上设置装配孔9，装配孔9用于联通液面保护罩3上部和下部金属熔体，热电偶5通过装配孔9或液面保护罩3与搅拌腔8内壁的间隙置于金属熔体中，用于测量金属熔体的温度。
电机6部件可以沿移动轨7上下移动，这样，电机6就能在驱动旋转轴2高速旋转的同时还带动它上下往复运动，进而旋转轴2可以带动切割片1在搅拌腔8内 高速旋转的同时还能沿轴向上下往复运动。在旋转轴2的金属液面10上方处，可以增加一个联轴器4，以快速连接和分开电机6部件，转移搅拌腔8内的熔体进行铸造。联轴器4的作用是实现本装置构造与旋转电机的输出轴进行快速的连接或分离。
如图1所示的装置中，还可以直接通过电机6的正反转交互变换实现旋转轴2相对于搅拌腔8的上下移动，或者采用一个升降台，将搅拌腔8置于升降台上，通过升降台的升降实现搅拌腔8相对于旋转轴2的上下往复移动，这样同样可以使电机6在驱动旋转轴2带动切割片1在搅拌腔8内高速旋转的同时还带动它们沿轴向相对于搅拌腔8上下往复运动。
如图1所示，切割片1似刀型(见A-A向)：其旋转前端锐利(或渐窄)，侧面呈斜面、水平面或曲面。在需要旋转轴2进行正反向交互变换旋转的情况下，采用的切割片1具有双向的尖锐旋转前端如图3-5所示。旋转轴2进行正反向交互变换旋转，例如上升时顺时针旋转，下降时逆时针旋转，或上升时逆时针旋转，下降时顺时针旋转。
切割片A-A向截面可以为矩形、三角形、菱形、类圆形等，如图3-1至图3-6所示。数个切割片1布置在一个或数个旋转面上。
本发明的切割片可在一个或数个旋转面上分层布置，相邻两层的切割片(上层切割片和下层切割片)之间，或者同一层的左切割片和右切割片(位于旋转轴两侧)之间，其旋转前端侧面的斜面方向可以相互呈反向对称布置。
如图4和图5所示，上层切割片11安装在旋转轴2的中上部位置，下层切割片安装在旋转轴2的下部位置，旋转轴2与联轴器4连接，上层切割片11，下层切割片的左切割片12，下层切割片的右切割片13，液面保护罩3以及旋转轴2均置于金属熔体的搅拌腔8内，上层切割片11，下层切割片的左切割片12，下层切割片的右切割片13均为刀型，旋转前端侧面为斜面。
本发明切割片装置的型号尺寸与熔体搅拌腔8的尺寸相匹配。
切割片旋转前端相对锐利，旋转前端的厚度≤5mm，侧面呈平面、斜面或曲面。切割片具有锐利或厚度极窄的旋转前端，就能使其在金属熔体中高速旋转时充分发挥“切割破散”的作用，产生的高强剪切力直接切割、破散熔体内所有的微小固相、第二相、氧化物、夹杂甚至分子有序排列，而且，该几何结构的旋转运动阻力极小，能极大降低液面翻腾现象。特别地，在某些应用场合，如果切割片的厚度很薄，则切割片的上下侧面可以都是平面(没有斜面或曲面)。
本发明的二层切割片沿旋转轴呈旋转对称分布，切割片侧面的斜度方向是根据 需要，在层间或同一层内的左右部分之间设计成相互呈反向对称布置。也就是说：上层切割片11(见图4A-A向，旋转前端侧面的斜面方向为向下)和下层切割片(见图4B-B向，旋转前端侧面的斜面方向为向上)之间、下层切割片的左切割片12(见图4C-C向，旋转前端侧面的斜面方向为向下)和右切割片13(见图4B-B向，旋转前端侧面的斜面方向为向上)之间，根据需要可以相互呈反向对称布置。
在层间，下层切割片旋转前端侧面的斜面方向向上(B-B向)，在高速旋转时，产生了对金属液向上的推动力；而上层切割片11旋转前端侧面的斜面方向却是向下的(A-A向)，同时产生了另一个对金属液向下的推动力。这两个相反的作用力使得金属熔体的内部激烈上下循环流动，并且极大抑制了金属液面的翻腾现象。同理，在下层左切割片12和下层右切割片13之间也进行了侧面斜面的反向对称布置的设计，这能进一步增强熔体内部的循环紊流，抑制液面翻腾。强烈的熔体内部的循环紊流，能显著增加熔体的均匀化处理效果；而微弱的液面翻腾，则有效消除了金属卷气卷渣。
因此，本发明的切割片装置能在整体高效切割处理金属熔体的同时，利用熔体自身的互逆“对流”来抑制金属液面翻腾而避免卷气卷渣，可广泛应用于连续铸造、压铸、锻铸、间歇式模铸等各种金属铸造场合。
液面保护罩3上设置装配孔9，装配孔9可用于联通保护罩上部和下部熔体。液面保护罩3的作用是进一步保护金属液面，完全消除液面翻腾。液面保护罩3可以呈平面或倒“U”形，浸没在金属液面下。液面保护罩3也可以固定安装在搅拌腔8内壁上。
所述的液面保护罩可以是定位式(见图1)、或活动的浮力舱式(见图6)，中部有收窄的装配孔9。
如图6所示，活动的浮力舱式液面保护罩，放置于熔体容器内，它由浮力舱21、立板22、装配孔9和挡圈23组成。立板22垂直连接在浮力舱21的一侧或两侧，并在浮力舱21上设置装配孔9。浮力舱21的形状与熔体容器的内壁轮廓相同。
需要说明的是，浮力舱21上装配孔9的形状将随熔体切割片机构的形状而定，以便于切割片机构在工作过程中下降进入和升出搅拌腔8。例如，当切割片机构的俯视图是一个长方形时，则装配孔的形状也是一个相适应大小的长方形形状。
例如，用活动的浮力舱式液面保护罩保护需要进行均匀化处理的铝合金熔体：立板22采用在浮力舱21上下两侧配置的形式，浮力舱21由钛合金薄板焊接成中空形式并填充轻质的硅酸铝耐热保温材料等制成。使用时，浮力舱式液面保护罩整体自动悬浮于铝合金液面上部，刀片状的熔体均匀化搅拌剪切处理机构从上方插入 到容器内的铝液中并进行高速旋转的均匀化处理。刀片的剪切搅拌作用虽然使隔离器下部的铝合金熔体发生搅拌扰动，但本隔离装置仍然能很好地隔离来自下部主熔体的旋转扭矩，起到了良好的稳定上部熔体液面的作用，使金属液面仍然保持静止。熔体均匀化处理结束后，将刀片式剪切搅拌机构从装配孔中提升出铝液，然后迅速转移容器的熔体进行浇铸。
如图7所示，本发明的上挡口24具有一定的厚度或深度，能使金属熔体的液面保持在上挡口24内；上挡口24的开口形状与切割片机构的形状相匹配，使熔体切割片机构能沿轴向自由进出搅拌腔8。
本发明的金属熔体容具和搅拌腔可采用如图8至图11所示的结构。图中所示搅拌腔室的构造是由熔体容具31、搅拌腔8、上挡口24、上阻滞凸棱32、下阻滞凸棱33、下底34、热电偶5和取液/浇注口35组成，搅拌腔8的上方是收窄的上挡口24，上挡口24的一端安装热电偶5，另一端为取液或浇注口35；此外，在搅拌腔8上方和下方的熔体容具31内壁，分别设置筋条状凸起的上阻滞凸棱32、下阻滞凸棱33，在熔体容具的下底34上也有下阻滞凸棱33。
如图8、图9所示；搅拌腔8的上方是收窄的上挡口24构造，以防止熔体液面产生搅拌漩涡和卷气。相比较宽敞的搅拌腔中部，收窄的上挡口24构造改变了搅拌腔8内熔体的流动场分布、封锁了搅拌流动向上方液面的传递路径。特别地，收窄的上挡口24具有一定的厚度或深度，使金属熔体的液面保持在上挡口24内，达到“宽大搅拌腔熔体”相对“窄小液面”的使用状态，而其它采用“液面保护罩”装置由于较薄而没有“收窄液面”的作用。上挡口24俯视图(见图8)的开口形状与切割片机构的形状相匹配，即能使熔体切割片机构自由进出搅拌腔8，又尽量收窄以达到最佳的阻隔搅拌效应的目的。在俯视图图8中，收窄的上挡口24的一端安装热电偶5，另一端为取液或浇注口35。此外，在搅拌腔8上方和下方的熔体容具31内壁，分别设置筋条状凸起的上、下阻滞凸棱(如图10和图11所示)，以进一步阻滞液面附近漩涡并增加搅拌剪切力，使搅拌产生更好的熔体均匀化处理效果。
该金属熔体搅拌腔在各种需要进行金属熔体搅拌铸造场合的应用：在压铸等间歇式铸造的场合，本搅拌腔构造就是浇注汤勺的内腔构造(只需对现有浇注汤勺按图9所示虚线添加活块即可)。使用时，首先从上挡口24的取液口舀取定量的金属液体，使液面保持在上挡口24内。将切割片机构自动旋转至与上挡口开口形状相匹配的方向，然后从上挡口自动插入切割片机构和定量长度的细化剂细丝(或投入定量重量的细化剂碎屑)，并在搅拌腔8内对金属熔体和正在快速熔化的细化剂实施强烈的均匀化搅拌。或者，细化剂丝材自身也可以高速旋转，成为切割片机构的 一部分，在熔体中边搅拌边进行均匀的熔化释放。当搅拌温度降低达到一个设定温度时，停止搅拌，从上挡口抽出切割片机构，然后迅速转移、倾转浇注汤勺进行铸造。
在连续铸造的场合，本搅拌腔就是熔体热顶的内腔构造，无需下底，可以直接将搅拌腔8与连铸结晶器对接；对于无搅拌器的电磁搅拌情形，上挡口24的开口形状可以是收窄的圆形或方形。使用时，金属熔体从上挡口24的取液口流入搅拌腔8，并使液面稳定维持在上挡口24内。当熔体温度达到设定的搅拌温度时，从上挡口24向熔体中自动插入切割片机构和细化剂丝材，在搅拌腔8内对金属熔体实施强烈搅拌，同时，移动引锭开始连续铸造，并不断进行连续供液、连续供丝和连续搅拌直至连铸过程结束，停止搅拌。最后从上挡口24抽出切割片机构。实现了在铸造现场的熔体搅拌处理—化学细化—浇铸整个过程的全自动化。
如图12所示，为采用本发明的装置进行金属熔体的切割破散处理与流变成形的方法，可用于在浇铸前均匀化处理金属熔体，包括如下步骤：
①.先将金属熔体所需添加剂丝材42，即细化剂、变质剂、微合金或复合材料颗粒等元素R(或其中间合金R)预热至50℃～TRL+50℃(TRL为R的液相线温度)。
②.对处于搅拌腔内即将铸造的金属熔体，实时按比例加入预热的R后，立即进行“切割破散”的均匀化处理；或者在处于搅拌腔内即将铸造的金属熔体中，按比例供给预热添加剂的同时，引入切割片机构进行切割破散的均匀化处理。如图12所示步骤1-2。对于压铸等间歇式铸造情形，搅拌腔8就是浇铸汤勺；对于连续铸造情形，搅拌腔8就是结晶器上方热顶。
③.熔体进行切割破散处理时，切割片机构在搅拌腔8内高速正、反向旋转的同时还沿轴向相对于搅拌腔8进行上下往复运动(电机6沿移动轨7上下移动带动旋转轴2上下移动，或通过电机6的正、反转实现旋转轴2的上下移动，或通过升降台的升降带动搅拌腔8上下移动，或其它移动方式)，如图12所示步骤2。通过切割片1的高速旋转和相对于搅拌腔8的上下移动，搅拌腔8内金属熔体液面附近的下方(或上方)装有液面保护罩3，液面保护罩3或上挡口24上有装配孔，可联通保护罩或上挡口上部和下部熔体；在熔体内形成无液面翻腾的可控多向紊流，同时还直接切割、破散熔体内的微小固相、第二相、氧化物和夹杂物，使凝固前金属熔体内的溶质高度弥散均匀化。熔体的“切割破散”处理方法区别于以往的“搅拌”理念，好比“搅蛋器”与“豆浆机”的区别。
④.对于压铸间歇式铸造(例如模铸)，搅拌腔8内是定量的金属熔体，添加剂R是“实时的”定量加入，熔体处理数秒或切割破散处理至熔体温度降低达到浇铸温 度T浇：TS＜T浇＜TL+50℃时(TS、TL分别为金属固、液相线温度)时，停止切割破散的均匀化处理，将切割片机构升出液面(或分开联轴器)，迅速转移搅拌腔(汤勺)并浇铸已高度均质化的金属熔体(T浇≥TL)或半固态浆料(TS＜T浇＜TL)。
对于连续铸造，金属熔体切割破散的均匀化处理是在热顶内连续运行，搅拌腔8内的金属熔体是连续流过，添加剂R的添加是按流量比例连续供给，切割破散的均匀化处理也是连续运行；直至连铸过程结束后，切割片机构停转并升出热顶，完成如图12所示步骤3。本流变成形技术的目的是获得均匀细小、优良致密的铸件凝固组织。
下面是采用金属熔体的切割破散装置与流变成形方法对AZ91镁合金进行实时均匀化处理并流变压铸汽车连杆的应用实例。
切割片装置采用3个切割片1(形状如图2所示，切割片似刀型(见A-A向)，旋转前端锋利，下侧面是水平面，上侧面是斜面)、3个旋转面、周向对称的结构布置。使用时：①.先将AZ91镁合金所需的细化剂元素C(1wt.％的Mg-Al-C中间合金)在保护气氛下预热至660℃(645℃为Mg-Al-C中间合金的液相线温度)。②.在SF6保护气氛下，用保温容器舀取定量的金属熔体950g，实时加入30g预热的C后，立即使用上述装置进行“切割破散”的均匀化处理。③.通过尖锐切割片1的高速旋转和匀速上下移动，不但在整体熔体内制造无液面翻腾的可控多向紊流，还直接切割、破散熔体内所有微小固相、第二相、氧化物、夹杂甚至分子有序排列，使铸造前金属熔体内的溶质高度弥散均匀化。④.切割破散处理直至合金温度降低达到浇铸温度605℃时(595℃为AZ91镁合金的液相线温度)，停止切割，分开联轴器4，迅速转移搅拌腔8将已高度均质化的镁合金熔体浇入压射腔中，快速压铸获得均匀细小、优良致密的铸件凝固组织。
本发明在金属熔体的高度分散、均匀化处理中，旋转轴可以带动切割片在搅拌腔内高速旋转的同时还能沿轴向上下往复运动。这种几何设计和工作方式，使得容腔内金属熔体经受的扰动是“范围和强度可控”的，且呈离心径向、旋转周向、上下轴向的多向紊流。这种可控紊流更配有液面保护罩，就能在整体均匀化处理金属熔体的同时，避免诸如其它发明是“搅拌翻腾”所引起的卷气卷渣弊端。进一步地，锐利切割片的高强剪切作用还直接切割、破散熔体内所有微小固相、第二相、氧化物、夹杂甚至分子有序排列，使铸造前金属熔体内的溶质高度弥散均匀化，在快速凝固后获得均匀细小、优良致密的铸件组织。因此，这种切割破散方法是在制造“可控紊流”的同时兼有“切割破散”效应。相比较其它借助电磁力或机械力对金属熔体实施单纯的“搅拌”处理方法，本发明简单高效，还引入独特的细化剂预热且在浇铸前实时 添加的方法。这些都在金属熔体处理和铸造的原理上实现了重要创新。
工业应用性
本发明的切割片装置能在整体高效切割处理金属熔体的同时，极大抑制金属液面翻腾而避免卷气卷渣，可广泛实时地应用于连续铸造、压铸、锻铸、模铸、复合材料制备等各种金属铸造场合。
以往的隔离器装置固定装配在容器内的一定位置，而本发明活动的浮力舱式液面保护罩通过对装置材料整体密度的调整设计来使装置稳定悬浮于熔体液面附近，它能够自动跟随熔体液面的高低变化而上下移动。本发明采用了像“船”一样的浮力舱构造：将上部的浮力舱做成一个密闭空腔，用于调节整个隔离器装置的平均密度，使装置能够自动悬浮于金属液面上部；浮力舱的中间空腔则充满轻质耐火保温材料，以排除内部空气，防止装置受热时膨胀。这样，调整装置整体的平均密度≤金属熔体密度，从而在使用过程中使本隔离器装置能始终自动悬浮于金属熔体的液面附近。
本发明活动的浮力舱式液面保护罩能将大体积熔体上部的液面部分与下部的主熔体隔离，有效阻隔主熔体受到剧烈搅拌时的扰动现象向上部液面传递，从而当主熔体中发生大的扰动对流时液面却仍然平静，达到稳定熔体液面的目的，同时防止熔体的氧化、卷渣和卷气等污染。
本发明用于搅拌金属熔体的搅拌腔可使搅拌腔内的熔体液面收窄，起到了有效阻隔搅拌效应向液面传递的作用，解决了熔体的氧化和卷气风险这个难题。本装置具有以下特点：
(1)“窄小液面”构造降低了熔体氧化吸气倾向，还阻断了搅拌流场向液面传递，使受到搅拌的金属熔体液面无翻腾无漩涡，避免了熔体氧化、卷气、卷渣。
(2)本装置实现了用于在浇注汤勺中的实时、自动喂给细化剂丝材的目的。
对从熔炼保温炉内流出或定量舀出的、即将铸造的金属熔体“实时”添加细化剂、微合金或复合材料颗粒等元素是本发明的主要创造之一。在金属连铸行业中，连续的“喂丝”就是一种实时的细化剂添加方法。但是，对于间歇式的“模铸”，细化剂等元素的添加一般是提前在熔炼保温炉内进行的，由于量大、铸造周期慢长，这就使得批次先后取出的金属熔体内的元素含量不均匀、偏析，甚至细化剂效果衰退。本发明理念是：首先在大熔炼保温炉内进行细化剂等元素的初步预混后，对定量取出且即将浇铸的熔体再次“实时的”进行余量的细化剂等元素添加，不但能充分保证批次的各元素组分含量均等，而且能最大程度地防止元素效力衰退。
对上述即将铸造的金属熔体进行实时的、促进各组分溶解扩散或分散的均匀化 处理是本发明的主要创造之二。为了能更好地促进元素溶解和熔体成分以及所有相的分布均匀，充分发挥各元素的特殊作用，在金属凝固前继续进行实时的均匀化处理是一种创新的技术理念。
金属熔体均匀化处理采用“切割破散”的方法与装置是本发明的主要创造之三。发明所设计的切割片装置似刀型：其旋转前端尖锐，产生的高强剪切作用能直接切割、破散熔体内所有微小固相、第二相、氧化物、夹杂甚至分子有序排列；如果切割片前端是渐窄的设计，可以用于分散、混合金属基复合材料；切割片的侧面呈斜面、水平面或曲面，根据调整不同的斜度和曲度来调整“搅拌”效应：斜度和曲度越大，则“搅拌翻腾”作用越剧烈；如果斜度很小接近于水平面，则旋转周向的流动接近层流。在适当侧面斜度和曲度的几何设计下，“切割破散”装置和方法使得容腔内金属熔体经受的扰动是“范围和强度可控”的，局部有序层流但整体紊流，旋转轴可以带动切割片在搅拌腔内高速旋转的同时还能沿轴向上下往复运动，就能将这种局部有序的可控流动施加到全部熔体中，无液面翻腾。因此，这种切割破散装置和方法是在制造“可控紊流”的同时兼有“切割破散”效应。相比较其它借助电磁力或机械力对金属熔体实施单纯的“搅拌”处理装置和方法，本发明简单高效，在金属熔体处理和铸造的原理上实现了重要创新。
本发明还具有以下优点：
1、结构简单，使用方便，处理效果优质高效。
2、能与各种铸造设备实现简单对接，工艺可控性强。
3、“切割破散”机制实现了对熔体的整体、强剪切均匀化处理。
4、实现了金属熔体添加剂在铸造时的“实时”加入技术。
5、无液面翻腾，消除了诸如其它搅拌引起的卷渣、卷气等污染。

Claims (22)

  1. 一种金属熔体均细化处理的切割破散装置，其特征在于：该装置包括切割片机构、搅拌腔、液面保护罩或上挡口、联轴器、添加剂机构和电机；所述的切割片机构主要包括旋转轴和切割片，所述的切割片安装在旋转轴上；所述的旋转轴与电机之间通过联轴器连接；所述的切割片机构设置在搅拌腔的轴向上，所述的液面保护罩或上挡口设置于搅拌腔内金属熔体液面的上方或下方。
  2. 根据权利要求1所述的金属熔体均细化处理的切割破散装置，其特征在于：所述的旋转轴可进行正向或反向旋转；通过多种方式，切割片机构可相对于搅拌腔沿轴向上下往复运动。
  3. 根据权利要求1所述的金属熔体均细化处理的切割破散装置，其特征在于：该装置还包括移动轨，所述的电机安装在可上、下移动的移动轨上。
  4. 根据权利要求1所述的金属熔体均细化处理的切割破散装置，其特征在于：该装置还包括升降台，所述的搅拌腔置于升降台上。
  5. 根据权利要求1-4中任一项所述的金属熔体均细化处理的切割破散装置，其特征在于：所述的切割片为刀型，旋转前端锐利，侧面呈斜面、水平面或曲面。
  6. 根据权利要求5所述的金属熔体均细化处理的切割破散装置，其特征在于：所述的切割片截面为矩形、三角形、菱形、圆形或类圆形。
  7. 根据权利要求6所述的金属熔体均细化处理的切割破散装置，其特征在于：所述的切割片布置在一个或数个旋转面上。
  8. 根据权利要求7所述的金属熔体均细化处理的切割破散装置，其特征在于：所述的切割片为复数个，在一个或数个旋转面上分层布置，相邻两层的切割片之间，或者同一层的左切割片和右切割片之间，其旋转前端侧面的斜面方向可以相互呈反向对称布置。
  9. 根据权利要求8所述的金属熔体均细化处理的切割破散装置，其特征在于：所述的切割片为二层，上层切割片和下层切割片之间，或者下层的左切割片和右切割片之间，其旋转前端侧面的斜面方向相互呈反向对称布置。
  10. 根据权利要求9所述的金属熔体均细化处理的切割破散装置，其特征在于：二层切割片沿旋转轴呈旋转对称分布。
  11. 根据权利要求10所述的金属熔体均细化处理的切割破散装置，其特征在于：所述切割片旋转前端相对锐利，旋转前端的厚度≤5mm。
  12. 根据权利要求1-4中任一项所述的金属熔体均细化处理的切割破散装置， 其特征在于：所述的液面保护罩为定位式或活动的浮力舱式，中部设有装配孔。
  13. 根据权利要求12所述的金属熔体均细化处理的切割破散装置，其特征在于：所述的液面保护罩呈平面或倒“U”形。
  14. 根据权利要求13所述的金属熔体均细化处理的切割破散装置，其特征在于：所述的液面保护罩浸没在金属液面下，或固定在搅拌腔内壁上。
  15. 根据权利要求12所述的金属熔体均细化处理的切割破散装置，其特征在于：所述的活动的浮力舱式液面保护罩主要由浮力舱、立板、装配孔和挡圈组成，立板垂直连接在浮力舱的一侧或两侧，并在浮力舱上设置有装配孔，所述立板相互交叉形成网格状稳定结构；所述浮力舱为密闭空腔，中间填充耐火保温材料；所述挡圈设置在浮力舱及装配孔的外周。
  16. 根据权利要求1所述的金属熔体均细化处理的切割破散装置，其特征在于：所述的上挡口具有一定的厚度或深度，金属熔体的液面保持在上挡口内；上挡口的开口形状与切割片机构的形状相匹配，使熔体切割片机构能沿轴向自由进出搅拌腔。
  17. 根据权利要求12所述的金属熔体均细化处理的切割破散装置，其特征在于：所述的切割破散装置还包括热电偶，所述的热电偶设置于搅拌腔内。
  18. 根据权利要求17所述的金属熔体均细化处理的切割破散装置，其特征在于：所述的热电偶通过液面保护罩或上挡口上的装配孔，或者通过液面保护罩或上挡口与搅拌腔内壁的间隙置于金属熔体中。
  19. 一种金属熔体均细化处理的切割破散与流变成形方法，包括如下步骤：
    ①先将金属熔体所需的添加剂预热；
    ②在处于搅拌腔内即将铸造的金属熔体中，实时按比例加入预热的添加剂后，进行切割破散的均匀化处理；或者按流量比例连续加入预热的添加剂，同时进行连续地切割破散的均匀化处理；
    ③进行切割破散时，旋转轴和切割片在搅拌腔内高速旋转的同时还沿轴向相对于搅拌腔进行上下往复运动，通过切割片的高速旋转和相对于搅拌腔的上下移动，在熔体内形成无液面翻腾的可控多向紊流，同时还直接切割、破散或分散熔体内的微小固相、第二相、氧化物和夹杂物，使铸造前金属熔体内的所有溶质或添加剂弥散均匀化；
    ④对于压铸等间歇式铸造，熔体处理数秒或熔体温度降低达到浇铸温度T浇时，停止切割破散的均匀化处理，将切割片机构升出液面或分开联轴器，浇铸已均质化的金属熔体或半固态浆料；对于连续铸造，金属熔体切割破散的均匀化处理连续运 行，直至连铸过程结束后，切割片机构停转并升出搅拌腔。
  20. 根据权利要求19所述的金属熔体均细化处理的切割破散与流变成形方法，其特征在于：所述的添加剂为细化剂、变质剂、合金或复合材料颗粒。
  21. 根据权利要求20所述的金属熔体均细化处理的切割破散与流变成形方法，所述的添加剂预热温度为50℃～TRL+50℃，TRL为添加剂的液相线温度。
  22. 根据权利要求19所述的金属熔体均细化处理的切割破散与流变成形方法，所述的浇铸温度TS＜T浇＜TL+50℃，TS、TL分别为金属的固、液相线温度。
PCT/CN2016/081982 2015-05-14 2016-05-13 金属熔体均细化处理的切割破散装置及流变成形方法 Ceased WO2016180362A1 (zh)

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