US20130118704A1 - Electromagnetically stirred sand castings - Google Patents

Electromagnetically stirred sand castings Download PDF

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Publication number
US20130118704A1
US20130118704A1 US13/293,198 US201113293198A US2013118704A1 US 20130118704 A1 US20130118704 A1 US 20130118704A1 US 201113293198 A US201113293198 A US 201113293198A US 2013118704 A1 US2013118704 A1 US 2013118704A1
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US
United States
Prior art keywords
mold body
induction coil
mold
coil embedded
cope
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.)
Abandoned
Application number
US13/293,198
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English (en)
Inventor
Junyoung Park
Jason Robert Parolini
Jon Conrad Schaeffer
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.)
General Electric Co
Original Assignee
General Electric Co
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 General Electric Co filed Critical General Electric Co
Priority to US13/293,198 priority Critical patent/US20130118704A1/en
Assigned to GENERAL ELECTRIC COMPANY reassignment GENERAL ELECTRIC COMPANY ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: PARK, JUNYOUNG, PAROLINI, JASON ROBERT, SCHAEFFER, JON CONRAD
Priority to CN201280055290.9A priority patent/CN103930224A/zh
Priority to PL12791377T priority patent/PL2817113T3/pl
Priority to PCT/US2012/064416 priority patent/WO2013071082A1/en
Priority to EP12791377.0A priority patent/EP2817113B1/de
Publication of US20130118704A1 publication Critical patent/US20130118704A1/en
Abandoned legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/02—Sand moulds or like moulds for shaped castings
    • 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
    • B22D27/02—Use of electric or magnetic effects

Definitions

  • the invention relates generally to electromagnetic stirring of metal castings. More particularly, the invention relates to a casting system, mold, and method for electromagnetically stirring sand castings.
  • Sand casting refers to a metal casting process that uses sand as the mold material.
  • a binder such as, e.g., clay or resin, may be mixed with sand, and the mixture may be moistened. This produces an aggregate material having suitable strength and plasticity to form the mold.
  • the sand material is packed around a pattern, and the pattern is subsequently removed, leaving a cavity in the mold.
  • molten metal is poured into the mold cavity through a gating system, and the molten metal is allowed to solidify in the mold.
  • a gating system such as steel components of, e.g., wind turbines, which may weigh upwards of 4,500 to 5,000 kg (about 10,000 to 11,000 pounds)
  • the solidification process may take several days to a week or more. After the casting has cooled, it can be shaken out of the mold.
  • the lengthy cooling time associated with sand casting presents several challenges. Steel and other alloy castings may be susceptible to segregation of elements during the cooling process due to different reactions. The longer cooling takes, i.e., the longer the cycle time, the greater the risk of this occurring. Elemental segregation can produce defects in the resulting casting that weaken the structure. Shrinkage defects may also occur when feed metal is unavailable to compensate for shrinkage as the metal cools and solidifies. These may naturally concentrate in the thermal center of the casting, which may disproportionately weaken that area of the resulting casting.
  • a first aspect of the disclosure provides a mold including a mold body having a cavity therein; the mold body further including a passageway fluidly connecting the cavity with an exterior of the mold, wherein the passageway allows for introduction of a molten metal into the cavity; and at least one induction coil embedded in the cope, or top half, of the mold, and at least one induction coil embedded in the drag, or bottom half, of the mold.
  • a second aspect of the disclosure provides a casting system comprising a mold body and a molten metal introduced into the mold.
  • the mold body may include: a cavity therein; a passageway fluidly connecting the cavity with an exterior of the mold body; and at least one fluid-cooled induction coil embedded in a cope of the mold body and at least one fluid-cooled induction coil embedded in a drag of the mold body.
  • the at least one fluid-cooled induction coil may be embedded in a cope of the mold body, and the at least one fluid-cooled induction coil may be embedded in a drag of the mold body to generate an electromagnetic field for stirring the molten metal during solidification of the molten metal.
  • a third aspect of the disclosure provides a method including: preparing a metal for casting, the preparing including melting the metal; introducing the molten metal into a cavity within a mold body; and using at least one induction coil, applying an electromagnetic field to the molten metal during solidification of the molten metal in the mold.
  • FIG. 1 shows a schematic drawing of an electromagnetic stirring apparatus in accordance with an embodiment of the disclosure.
  • FIG. 2 shows a three-dimensional drawing of an electromagnetic stirring apparatus in accordance with an embodiment of the disclosure.
  • FIG. 3 shows a flow chart depicting a process according to an embodiment of the disclosure.
  • aspects of the invention provide a casting system and mold structure for producing metal castings, shown in FIGS. 1-2 as well as a method of casting, shown in FIG. 3 .
  • casting system 100 includes mold body 110 .
  • mold body 110 may be made of sand, and my include resin as a binder.
  • Other possible binders may include clay, oil, or sodium silicate, among other binders.
  • Mold body 110 includes cavity 120 disposed therein, which may take a regular or irregular shape as appropriate to the three-dimensional shape of the desired casting.
  • a gating or passageway 130 fluidly connects cavity 120 with an exterior 140 of mold body 110 . Passageway 130 allows for the introduction of molten metal 125 into cavity 120 .
  • Metal 125 can be any metal, and may particularly be an alloy such as, e.g., steel, any ferrous metal, or any nonferrous, conductive metals.
  • At least one induction coil 150 may be embedded in cope 155 of mold body 110
  • at least one induction coil 160 may be embedded in drag 165 of mold body 110
  • Each induction coil 150 , 160 is disposed about cavity 120 or a feature thereof.
  • the number of coils 150 , 160 applied can vary depending upon the specific geometries of cavity 120 and therefore metal 125 . For example, if cavity 120 and metal 125 have a feature or features that require specific properties, an induction coil 150 , 160 may be applied to each feature.
  • Induction coils 150 , 160 are fluid-cooled.
  • the fluid may be water. More specifically, in some embodiments, deionized water may be used.
  • induction coils 150 and 160 are low-frequency induction coils, operating at a frequency of, e.g., about 20 Hz to about 10 kHz.
  • Induction coils 150 , 160 may further have a cross-sectional diameter of between about 5 and about 30 mm, and may have either a round or a rectangular cross sectional shape.
  • induction coils 150 , 160 are made of copper, and coated with ceramic, providing improved heat resistance.
  • induction coils 150 , 160 may be used to generate an electromagnetic field 170 which stirs metal 125 in cavity 120 as metal 125 solidifies. Stirring of metal 125 by electromagnetic field 170 serves to homogenize the cast structure, and thus minimizes the degrading effects of segregation in the metal 125 casting. Electromagnetic stirring further disperses any instances of shrinkage defects throughout the metal 125 casting, rather than allowing them to concentrate in the thermal center of the metal 125 casting. The resulting metal 125 casting demonstrates improved endurance limits for tramp elements. Further, metal 125 casting may have a finer grain structure, a reduction in the percentage of porosity, and improved mechanical properties as a result of the increased cooling rates. Faster cooling also decreases cycle time, increasing process efficiency.
  • step 51 metal is melted and prepared for casting.
  • the metal prepared may be an alloy such as, e.g., steel.
  • step S 2 the molten metal is introduced into a cavity in a mold.
  • the mold may include sand.
  • an electromagnetic field is generated and applied to the metal, stirring it while it solidifies within the mold.
  • the electromagnetic field may be generated by at least one induction coil.
  • step S 4 the metal is cooled in substantial part by fluid flowing through the induction coils, which act as a cooling element.
  • the fluid may be water, or more specifically, deionized water.
  • step S 5 the metal casting can be removed from the mold.
  • electromagnetically stirred sand castings may be produced.
  • first do not denote any order, quantity, or importance, but rather are used to distinguish one element from another
  • the terms “a” and “an” herein do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced item.
  • the modifier “about” used in connection with a quantity is inclusive of the stated value and has the meaning dictated by the context (e.g., includes the degree of error associated with measurement of the particular quantity).

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Continuous Casting (AREA)
US13/293,198 2011-11-10 2011-11-10 Electromagnetically stirred sand castings Abandoned US20130118704A1 (en)

Priority Applications (5)

Application Number Priority Date Filing Date Title
US13/293,198 US20130118704A1 (en) 2011-11-10 2011-11-10 Electromagnetically stirred sand castings
CN201280055290.9A CN103930224A (zh) 2011-11-10 2012-11-09 电磁搅拌砂型铸件
PL12791377T PL2817113T3 (pl) 2011-11-10 2012-11-09 Mieszane elektromagnetycznie odlewy w formach piaskowych
PCT/US2012/064416 WO2013071082A1 (en) 2011-11-10 2012-11-09 Electromagnetically stirred sand castings
EP12791377.0A EP2817113B1 (de) 2011-11-10 2012-11-09 Elektromagnetisch gerührte sandformkörper

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
US13/293,198 US20130118704A1 (en) 2011-11-10 2011-11-10 Electromagnetically stirred sand castings

Publications (1)

Publication Number Publication Date
US20130118704A1 true US20130118704A1 (en) 2013-05-16

Family

ID=47226460

Family Applications (1)

Application Number Title Priority Date Filing Date
US13/293,198 Abandoned US20130118704A1 (en) 2011-11-10 2011-11-10 Electromagnetically stirred sand castings

Country Status (5)

Country Link
US (1) US20130118704A1 (de)
EP (1) EP2817113B1 (de)
CN (1) CN103930224A (de)
PL (1) PL2817113T3 (de)
WO (1) WO2013071082A1 (de)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20130277007A1 (en) * 2012-04-20 2013-10-24 Fs Precision Tech Single piece casting of reactive alloys

Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4133371A (en) * 1976-08-31 1979-01-09 Rolls-Royce Limited Casting
US4605054A (en) * 1983-09-26 1986-08-12 Kawachi Aluminium Casting Co., Ltd. Casting apparatus including a conductor for electromagnetic induction heating
US4766664A (en) * 1987-02-17 1988-08-30 Alumax Extrusions, Inc. Process for formation of high strength aluminum ladder structures
US5062386A (en) * 1987-07-27 1991-11-05 Epitaxy Systems, Inc. Induction heated pancake epitaxial reactor
US20100025005A1 (en) * 2008-08-04 2010-02-04 Jiangsu Jixing Wind Turbines Limited Method for Casting High-Power Wind Turbine Base with Ductile Iron
US20100159197A1 (en) * 2007-06-20 2010-06-24 Novative Properties Company Ultrasonic injection molding on a web
US20110272593A1 (en) * 2010-05-05 2011-11-10 Tel Epion Inc. Gas cluster ion beam system with cleaning apparatus

Family Cites Families (8)

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Publication number Priority date Publication date Assignee Title
US475498A (en) * 1892-05-24 Process of rendering iron
JPH01192462A (ja) * 1988-01-26 1989-08-02 Toyota Motor Corp アルミニウム合金鋳物の製造方法
JPH0871731A (ja) * 1994-08-31 1996-03-19 Aisin Takaoka Ltd 鋳造方法
CN1583325A (zh) * 2003-08-20 2005-02-23 上海海立铸造有限公司 一种灰口铁缸体的精密铸造工艺
CN101032740A (zh) * 2006-03-07 2007-09-12 南开大学 连铸坯纵向电磁搅拌装置
CN101486073B (zh) * 2008-12-04 2010-09-29 苏州明志科技有限公司 一种电磁金属型及其制造方法
CN201308985Y (zh) * 2008-12-17 2009-09-16 中国科学院金属研究所 一种低压脉冲磁场凝固装置
WO2011058568A1 (en) * 2009-11-16 2011-05-19 Netanya Plasmatec Ltd. Treating and stirring metal parts cast in non-conductive mold

Patent Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4133371A (en) * 1976-08-31 1979-01-09 Rolls-Royce Limited Casting
US4605054A (en) * 1983-09-26 1986-08-12 Kawachi Aluminium Casting Co., Ltd. Casting apparatus including a conductor for electromagnetic induction heating
US4766664A (en) * 1987-02-17 1988-08-30 Alumax Extrusions, Inc. Process for formation of high strength aluminum ladder structures
US5062386A (en) * 1987-07-27 1991-11-05 Epitaxy Systems, Inc. Induction heated pancake epitaxial reactor
US20100159197A1 (en) * 2007-06-20 2010-06-24 Novative Properties Company Ultrasonic injection molding on a web
US20100025005A1 (en) * 2008-08-04 2010-02-04 Jiangsu Jixing Wind Turbines Limited Method for Casting High-Power Wind Turbine Base with Ductile Iron
US20110272593A1 (en) * 2010-05-05 2011-11-10 Tel Epion Inc. Gas cluster ion beam system with cleaning apparatus

Non-Patent Citations (2)

* Cited by examiner, † Cited by third party
Title
Induction heating fundamentals, http://web.archive.org/web/20090216045633/http://ameritherm.com/aboutinduction.php, 2/16/09 *
Induction Heating, http://www.gpgyjr.com.cn/, 7/21/10 *

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20130277007A1 (en) * 2012-04-20 2013-10-24 Fs Precision Tech Single piece casting of reactive alloys

Also Published As

Publication number Publication date
EP2817113B1 (de) 2020-10-14
CN103930224A (zh) 2014-07-16
WO2013071082A1 (en) 2013-05-16
PL2817113T3 (pl) 2021-04-19
EP2817113A1 (de) 2014-12-31

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Owner name: GENERAL ELECTRIC COMPANY, NEW YORK

Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:PARK, JUNYOUNG;PAROLINI, JASON ROBERT;SCHAEFFER, JON CONRAD;REEL/FRAME:027293/0275

Effective date: 20111109

STCB Information on status: application discontinuation

Free format text: ABANDONED -- AFTER EXAMINER'S ANSWER OR BOARD OF APPEALS DECISION