Method and apparatus for making metal alloy castings

Details Method and apparatus for making metal alloy castings Method and apparatus for making metal alloy castings

B - Operations, Transporting

22

D

B22D 11/112 (2006.01) B22D 11/00 (2006.01) B22D 11/06 (2006.01) B22D 17/00 (2006.01)

Patent

CA 2417822

A method and apparatus are provided for fabricating of continuous castings with fine and uniform microstructure, which can be used as feedstock for secondary processing routes, such as thixoforming, forging and machining or direct application in industry. An overheated liquid alloy is fed into a high shear device (for example, a twin-screw extruder) and sheared intensively to produce a sheared liquid alloy or a semisolid slurry, wherein the sheared liquid alloy is at a temperature close to its liquidus and the semisolid slurry is then transferred to a shaping device for production of continuous castings with fine and uniform microstructures through a solidification process. The shaping device is any device capable of forming continuous (i.e. infinite length) products, such as a direct chill (DC) caster (2) (DC rheocasting) for production of continuous billets, an extrusion die (8) (rheo- extrusion) for production of continuous bars or wires, or a twin-roll caster (twin-roll rheocasting) for producing of continuous strips. In all those cases, the cross-section of the continuous castings exhibits a microstructure in which a controlled volume fraction of fine and spherical primary particles are uniformly distributed in a fine structured matrix.

L'invention porte sur un procédé et un appareil de fabrication en continu de produits coulés de microstructure fine et uniforme pouvant alimenter des trains secondaires de traitement tels que le thixoformage, le forgeage, l'usinage, ou servir directement dans l'industrie. A cet effet on place l'alliage liquide surchauffé dans une machine provoquant un fort cisaillement telle qu'un extrudeur à double vis pour obtenir un alliage liquide ou une boue semi-solide cisaillés à une température proche de son liquidus, la boue semi-solide étant alors transférée dans un appareil formage produisant au cours du processus de solidification des produits coulés de microstructure fine et uniforme. Le dispositif de formage peut être tout dispositif de formage continu (c.-à-d. en éléments sans fin) par exemple une couleuse (2) à refroidissement direct produisant des billettes en continu, ou une filière (8) d'extrusion (rhéoextrusion) produisant des barres ou des fils, ou une couleuse à double vis (rhéocoulage à double vis) produisant des bandes continues. Dans tous ces cas, la section transversale de la pièce coulée présente une microstructure dans laquelle la fraction de volume contrôlé de particules primaires fines et sphériques est répartie uniformément dans une matrice finement structurée.

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