US3592636A - Manufacture of alloys - Google Patents

Manufacture of alloys Download PDF

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Publication number
US3592636A
US3592636A US771028A US3592636DA US3592636A US 3592636 A US3592636 A US 3592636A US 771028 A US771028 A US 771028A US 3592636D A US3592636D A US 3592636DA US 3592636 A US3592636 A US 3592636A
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Prior art keywords
rod
melt
metal
alloying
vibration
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US771028A
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English (en)
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Reimar Pohlman
Klaus Groove
Walter Fichtl
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Groove and Welter
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Groove and Welter
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    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C1/00—Making non-ferrous alloys
    • C22C1/02—Making non-ferrous alloys by melting

Definitions

  • the alloying of metals normally requires several process steps, especially since with higher melting components long dissolving times are necessary, and accuracy of the desired alloying concentration cannot generally be attained in one melting process.
  • the procedure is thus first to manufacture a pre-alloy of higher concentration and this is immersed, either fluid or solid into a melting bath in which the finished alloy is produced. In this, a control analysis of the concentration of the alloy obtained is generally necessary, since metal losses, eg by burn off of the product, can occur.
  • the manufacture of alloys with very small concentrations of alloying components presents, for these reasons, special difficulties.
  • a method for the homogenisation of a melt by ultrasonic excitement has also been described in which at least one of the fluid alloy components is blown into the other component or components by a pipe or nozzle arrangement.
  • attempts have been made to build a body of alloying metal into the floor or a melting vessel so that on excitement by ultrasound of the fluid melt surrounding it, it is dispersed or dissolved. It has also been proposed, without the use of ultrasound, to make possible a one-step alloying process by introducing a measured amount of fluid alloying metal into the base metal by means of special apparatus.
  • the invention has for its special purpose that of enabling an introduction or exact dosing of alloying components of high melting point into a base metal of low melting point in simple and economic fashion.
  • a process for introducing a controlled quantity of a high melting metal component into a melt of a low melting base metal which comprises feeding a rod of the high melting component into the said melt while subjecting the said rod to sonic vibration and at the same time cooling the rod which extends above the surface of the melt.
  • the rate of cavitation-produced solution of the metal rod thus achieved is controlled by adjustment of the depth of immersion of the rod in the melt and by adjustment of the exciter frequency of an oscillation generator used to provide the sonic vibration.
  • the excitation frequency of the vibration generators is automatically made to be the natural frequency of the vibration system, varying during solution, of the rod.
  • ultrasonic vibrations are preferred, and the invention will therefore be explained especially with reference to the use of ultrasonic vibrations.
  • At least the lowest part of the vibration system is constituted by a rod of the metal to be introduced, which on excitation with a definite ultrasonic energy dissolves on immersion in the melting bath, the solution of the material of the rod caused by cavitation being so controlled that an optimum dissolution velocity and a regular dissolution of the immersed portion of the rod are obtained.
  • the rod By the immersion of the rod, which constitutes a part of the ultrasonic system, the rod itself tends to become very strongly heated, as a result of its high thermal conductivity. This circumstance causes an increase in the damping of the vibration, with consequent reduction in the solution velocity. By shorting the rod as a result of dissolution, the natural frequency of the whole system changes, and this again reduces the solution velocity. It is optionally desirable so to control the solution of the immersed rod, that the rod shortens itself at a constant cross-section and that metal removal takes place only at the face of the end of the rod. Without such control there is a tendency for metal to be removed from the lateral surface(s) of the rod and this can lead to pieces of the rod breaking away and either sinking or floating in the melt as not yet dissolved compact pieces of metal.
  • the process of the present invention in the control of the foregoing contrary influences on the direct vibration of the metal to be introduced, so that a maximum dissolving power of the metal, with a high rate of removal and a minimum alloying time, can be obtained, and so that the process is effective for large-scale use.
  • the higher melting metal component is introduced from above into the melt of the lower melting component, as an automatically tuned ultrasonically excited vibration element, cooled until just above the melt surface, with a drive corresponding to the solution rate, and is dissolved therein.
  • an apparatus for carrying out the process, an apparatus, the essential components of which consist of a compound rod-shaped vibration system, which includes a rod, preferably of several half-wavelengths long, of especially low acoustic damping, and integrally connected thereto, a similarly rodshaped piece of the metal to be vibrated and and adjustable advancing device.
  • the compound rod-shaped vibration system is held at two points in as damping-free a way as possible, and is cooled in the working position to just above the melt surface.
  • the compound vibration system is excited with the aid of ultrasonic exciter, intensively at its natural frequency, and so that the rod is led in a vertical guide by means of a infinitely variable regulatable drive into the lower melting components in molten state, from above, with a speed which corresponds to the dissolution speed of the metal of the rod.
  • the rod of length several half-wavelengths is suitably provided at the excitation end with a pickup, which controls the high frequency generator serving for the excitation in such fashion that the excitation frequency of the generator automatically follows the varying natural frequency of the vibration system.
  • the ultrasonic excitation thus remains constant despite the dissolution and shortening of that part of the rod dipping into the melt.
  • the excitation frequency can also be controlled by a time or weight regulated device, which for .a constant dissolution velocity also shortens the vibration element with a constantly maintained speed.
  • the control of frequency can result in simple fashion from the constant decrease in the weight or buoyancy of the vibration element dipping into the melt.
  • the dissolution velocity of the metal of the rod increases, for a given sonic power, with increasing temperature of the metal of the rod and of the surrounding melt of base metal.
  • the ultrasonic transfer in the metal of the rod decreases with rising temperature, so that insutficient sonic power is obtained at the face of the rod.
  • a well determined cooling of the rod, and therewith an optimum temperature reflection at the face is of decisive importance.
  • this material-dependant temperature reflection should be kept as high and as constant as possible.
  • FIG. 1 of the drawings there is illustrated an example of an apparatus according to the invention.
  • a sonic or magnetostrictive ultrasonic generator is designated 1,
  • a housing 1a which is surrounded by a housing 1a, and which, for example, can operate in the region between 5 and 60 kc./s. It is rigidly connected to a rod 2 of length greater than half a wavelength, to the lower end of which a rod-shaped piece 3 of an alloy metal to be vibrated is attached, e.g. screwed to the rod 2, as is indicated by 18.
  • the resulting composite ultrasonically excited vibration system can be driven via a spindle 4 with the aid of a drive 5, driven by an electric motor and adjustable infinitely variable, on sliding collars 6 along a vertical guideway 7 (having three columns), into the melt 8, or, after ending of the process driven out again in fast drive.
  • a pickup 9 which can control the high frequency excitation generator.
  • the whole apparatus is mounted on the lid 10 of a melting crucible 11 and extends through an opening in the lid 10 into the melting chamber of the crucible 11, the end of the rod 3 of alloy metal dipping into the melt of base metal 8.
  • the ultrasonic exciter 1 is sprayed with a cooling agent such as cooling water by a spray 12. If necessary, it can also be cooled by the use of a gaseous cooling agent.
  • the spray cooling provided is essentially more advantageous than, for example, a conventional immersion cooling in water, because in the latter a great deal of the acoustic power generated is led away to the surrounding water and housing, which is not the case in a spray process.
  • the rod-shaped sonic transmitter 2 is led through into the housing 1 or by means of or through an opening having an elastic seal 13.
  • the seal 13 can, for example, consist of a rubber ring, and is on the one hand especially poor in damping and thus removes almost no energy from the vibrating system, and on the other hand allows the reliable collection of the cooling water, which can be led away via apipe 14.
  • a further spray 12 is provided for trapping the heat conducted up from the melt 8 and the radiated heat, which is arranged in a vessel 15 surrounding the joint between rod 2 and rod 3, by means of which the water running away can be caught by a holder and seal 13.
  • a suction tube 14 serves to maintain the water level low, in order to avoid ultrasonic dissipation in the vessel 15.
  • the vessel 15 is surrounded by a polished reflective housing 16, and at its base is isolated from the housing 16 by means of an intermediate asbestos ring 17, so that both heat radiation and heat conduction are greatly diminished.
  • thermal differences between the metal rod 3 and the rod 2 are avoided by cooling of the joint with which the rod 3 of the alloying metal is acoustically rigidly joined to the rod 2, so that the acoustic transfer at this point is held very constant.
  • An especial advantage of the apparatus according to the invention consists in that each part of the system which is important for good transfer of the high ultrasonic power remains cool and thus free of damping, despite the heat lost from the ultrasonic exciter from above and the heat conducted away from the melt.
  • a further advantage of the apparatus according to the invention can be seen in that a large relative change of the rod 3 introduced into the base metal melt, results in only a small relative change, and thus a controllable frequency change of the whole vibration system, consisting of the ultrasonic exciter 1, the vibration transmitter 2 and the rod 3.
  • the rod 3 can be constructed in various way.
  • the rod can be solid, or in some cases hollow.
  • the rod can consist of two or more alloy components. Further, particular sections or annuli of the alloying metal rod can consist of different materials.
  • FIG. 2 shows schematically the circuit principles of automatic frequency control for an ultrasonic generator.
  • the ultrasonic generator is designated 1 and a rod more than several half wavelengths long serving as vibration conductor is designated 2, to the end of which is joined a rod shaped piece of alloying metal to be vibrated (here not shown).
  • a pickup 9 is fixed to the excited end of rod 2.
  • the pickup 9 (electromagnet transducer) transmits electrically the feed back voltage taken from the rod 2 to a device 19 for automatic resonance tuning.
  • device 19 the feedback voltage is amplified, before it is led to the high frequency generator 20', and the phase is corrected by a phase adjuster, so that the high frequency excitation and the ultrasound oscillate in phase.
  • FIGS. 3 to 6 there are illustrated four rod pieces of vibrated, or to be vibrated, alloying metal in transverse section.
  • the rod piece 21 of alloying metal has a thread 18 on its upper end, which can be screwed into a rod 2 serving as vibration conductor (FIG. 1).
  • a rod 2 serving as vibration conductor (FIG. 1).
  • metal is dissolved from rod piece 21 in a metal melt by the action of the ultrasonic vibrations.
  • the face 22 is almost evenly worn away, and shows only a rough surface caused by the action of cavitation consisting of many small craters.
  • the rod piece 21 is, according to the process of the invention, regularly cooled down to just above the molten melt.
  • FIG. 4 there is shown a corresponding rod piece 23 of alloying metal, as is obtained by dipping the rod piece of alloying metal excited by ultrasonic vibrations without the application of cooling. It is clearly evident that the metal removal at the face 24 is wholly irregular.
  • FIG. 5 shows a rod piece 25 which is constructed from two different alloying metals.
  • the rod piece 25 has an outer sleeve portion 26 of an alloy X and a core piece 27 of an alloy Y.
  • FIG. 6 shows a rod piece 28 of alloying metal which is hollowly constructed. The upper end of the tubular rod is closed and bears the thread 18, which is screwable into the rod 2 which acts as a vibration conductor.
  • the advantages of the method of the invention are multiple: It allows the manufacture, as mentioned above, of alloys in which the great difference between the melting points of the alloy components would lead in conventional alloying to an uneconomically high burnotf, and it achieves this without the use of protective gas, which substantially eases the working conditions. Additionally, the process according to the invention allows an excellent control of the dosage of the rod metal, especially when the closely controllable apparatus described is used. This dosage is accurate since both the time of vibrating, and the intensity of the ultrasonic excitement, can be adjusted to zero, and without vibration the higher melting component practically does not dissolve in the lower melting component over a short period of time. On the basis of this exact dosage possibility, there appears the further advantage that the normally necessary analysis of the pre-prepared alloy can be avoided. The process makes it possible to establish a very high degree of homogeneity and to obtain very fine and regular dispersions, even with metals of very different density.
  • the process and apparatus according to the present invention are thus suitable for accurate and rapid alloying, especially for small alloying concentrations.
  • a small concentration of alloying metal e.g. a concentration of less than 1%
  • one is compelled after alloying a small concentration of alloying metal, e.g. a concentration of less than 1%, to take a test for control analysis prior to pouring the melt, wherein one strives toward the lower limit of content in the base metal, in order, if necessary to be able to correct the concentration by additional alloying.
  • a pre-alloy of higher concentration casts this alloy to slabs or bars, in order then in the manufacture of the final alloy, to achieve an accurate end alloy with the aid of the pre-alloy slabs.
  • control analysis before casting is still not unnecessary, since varying metal losses can arise, especially in multitage alloying processes.
  • rods can also be alloyed into a base melt by direct vibration, which consist of one metal alloy or of several metals put together in sections, so that a multicomponent alloy can be manufactured in one process.
  • NE-metals e.g. zinc
  • the ageing resistance of zinc-copper alloys can be importantly influenced by an iron or titanium content of 0.02%.
  • EXAMPLE This example illustrates the manufacture of a zinc alloy of pure zinc with 0.15% titanium and 0.60% copper.
  • the rods illustrated in FIGS. 3 and 4 consist, for example, of titanium with a purity of 99.4% Ti and 0.25% Fe and are suitable for the manufacture of a zinc-titanium alloy.
  • the rods in FIGS. 3 and 4 can consist, for example, of a nickelchromium alloy with 76% nickel and 15% chromium.
  • the rod in FIG. 5 consists, for example, of a sleeve portion 25 of pure aluminium with a purity of 99.5% Al, while the core is constructed of magnesium with a purity of 99.8% Mg.
  • This rod is provided for the manufacture of a zinc-aluminium-magnesium finished alloy.
  • the rod of FIG. 6 consists, for example of magnesium with a purity of 99.8% and is tubularly constructed, in order, for example, to attain very precise dosages by means of a decreased rod face area, and also, if necessary, to serve as a bell filled with protective gas.
  • a process for introducing a controlled quantity of a high melting metal component into a melt of low melting base metal which comprises feeding a rod of the high melting component into the said melt while subjecting the said rod to sonic vibration and at the same time cooling the part of the rod which extends above the surface of the melt.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Manufacture And Refinement Of Metals (AREA)
  • Apparatuses For Generation Of Mechanical Vibrations (AREA)
US771028A 1967-10-31 1968-10-28 Manufacture of alloys Expired - Lifetime US3592636A (en)

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US64887A Expired - Lifetime US3682459A (en) 1967-10-31 1970-07-27 Manufacture of alloys

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Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4136696A (en) * 1975-04-15 1979-01-30 International Paper Company Self-contained, combined irrigator and evacuator for wounds
RU2210611C2 (ru) * 2001-08-31 2003-08-20 Региональный общественный фонд содействия защите интеллектуальной собственности Способ модифицирования алюминиевых сплавов
WO2008075995A1 (en) * 2006-12-19 2008-06-26 Advanced Alloys Sa Method for obtaining alloying additives used for producing alloys

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DD161221A1 (de) * 1982-04-06 1985-06-26 Mansfeld Kombinat W Pieck Veb Zufuehreinrichtung fuer schmelzoefen, insbesondere fuer plasmaschmelzoefen
EP4725624A1 (de) 2024-10-14 2026-04-15 Amazemet Spolka Z Ograniczona Odpowiedzialnoscia Verfahren zur zerstäubung eines pulverförmigen rohmaterials und vorrichtung zur zerstäubung eines pulverförmigen rohmaterials

Family Cites Families (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2577837A (en) * 1949-10-29 1951-12-11 Lothar R Zifferer Introduction of magnesium into molten iron
US3273212A (en) * 1959-01-16 1966-09-20 Republic Steel Corp Method of operating an electric furnace
US3275787A (en) * 1963-12-30 1966-09-27 Gen Electric Process and apparatus for producing particles by electron melting and ultrasonic agitation

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4136696A (en) * 1975-04-15 1979-01-30 International Paper Company Self-contained, combined irrigator and evacuator for wounds
RU2210611C2 (ru) * 2001-08-31 2003-08-20 Региональный общественный фонд содействия защите интеллектуальной собственности Способ модифицирования алюминиевых сплавов
WO2008075995A1 (en) * 2006-12-19 2008-06-26 Advanced Alloys Sa Method for obtaining alloying additives used for producing alloys

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US3682459A (en) 1972-08-08
AT285186B (de) 1970-10-12
DE1608152A1 (de) 1970-11-12
DE1608152B2 (de) 1973-03-29
DE1608152C3 (de) 1973-10-18

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