Semi-liquid metal processing and sensing device and method of using same
원문보기
IPC분류정보
국가/구분
United States(US) Patent
등록
국제특허분류(IPC7판)
C22B-009/22
C22B-021/06
B22D-041/01
F27B-014/20
출원번호
US-0477298
(2012-05-22)
등록번호
US-8728196
(2014-05-20)
발명자
/ 주소
Koch, Alan A.
출원인 / 주소
Ajax TOCCO Magnethermic Corporation
대리인 / 주소
Fay Sharpe LLP
인용정보
피인용 횟수 :
0인용 특허 :
21
초록▼
A semi-liquid metal processing and sensing device comprising a crucible that is at least partially encircled by at least one induction coil. The one or more induction coils can be water cooled. The one or more induction coils can be designed to generate a variable power and/or variable frequency mag
A semi-liquid metal processing and sensing device comprising a crucible that is at least partially encircled by at least one induction coil. The one or more induction coils can be water cooled. The one or more induction coils can be designed to generate a variable power and/or variable frequency magnetic field which can be modulated to control the cooling of a molten metal charge in the crucible from the liquidus temperature to a selected heat content, resistivity and/or viscosity. The magnetic field can be designed to induce toroidal agitation of the metal charge in the crucible. The semi-liquid condition is sensed and can be actively controlled by the induction power supply via real time or non-real time analysis of electrical feedback signals that are obtained from the induction coil.
대표청구항▼
1. A method of monitoring, determining, controlling, and combinations thereof at least one property of a molten or semi-molten material in a material container that is subjected to a magnetic field formed by at least one induction coil to control a cooling rate of said material in said material cont
1. A method of monitoring, determining, controlling, and combinations thereof at least one property of a molten or semi-molten material in a material container that is subjected to a magnetic field formed by at least one induction coil to control a cooling rate of said material in said material container, said method including: inserting said molten or semi-molten material in a cavity of said material container, said cavity at least partially encircled by at least one induction coil;applying power to said at least one induction coil, said at least one induction coil functions as a heating device, a cooling device, and combinations thereof of said material;directly sensing, indirectly sensing, and combinations thereof at least one electrical parameter as said power is applied to said at least one induction coil, said sensing of said at least one electrical parameter is obtained from i) feedback from said at least one induction coil, ii) information from a solenoid coil in proximity to said at least one induction coil, or combinations thereof; and,determining a load resistance inside a region at least partially encircled by said induction coil, a resistivity of said material, a temperature of said material, a solid fraction of said material, a liquid fraction of said material, and combinations thereof based at least partially on said sensed at least one electrical parameter at least while said solids fraction of said molten or semi-molten material increases while in said cavity of said material container. 2. The method as defined in claim 1, including the step of using said sensed at least one electrical parameter to at least partially control said material temperature, said solid fraction of said material, said liquid fraction said material, and combinations thereof in said material container. 3. The method as defined in claim 1, wherein said material is inserted in said material container is at a temperature above a solidus temperature of said material. 4. The method as defined in claim 1, wherein said material is pure aluminum or an aluminum alloy, said aluminum alloy including at least 77.55 weight percent aluminum and at least two metals selected from the group consisting of copper, iron, magnesium, manganese, nickel, silicon, tin, titanium and zinc. 5. The method as defined in claim 1, wherein said material is at least partially stirred in said material container by a magnetic field generated by said at least one induction coil. 6. The method as defined in claim 1, including the step of using said sensed at least one electrical parameter to at least partially control a power level to said at least one induction coil. 7. The method as defined in claim 6, wherein said step of controlling said power level is used to control a reduction of said temperature of said material to a temperature greater than a solidus temperature of said material so that said material has a certain solid fraction and liquid fraction just prior to a time said material is poured from or otherwise ejected from said material container. 8. The method as defined in claim 1, including the step of continuously or periodically monitoring said sensed at least one electrical parameter while said material is in said material container to track a temperature trend of said material in said material container. 9. The method as defined in claim 1, including the step of determining a derivative of said sensed at least one electrical parameter as a function of time and using said derivative to at least partially determine a temperature trend over time of said material in said material container. 10. The method as defined in claim 1, including the step of setting a target electrical parameter and controlling said power level to said at least one induction coil so that said temperature of said material in said material container obtains a certain temperature to cause said sensed at least one electrical parameter to equal said target electrical parameter. 11. The method as defined in claim 1, including the step of setting a target cycle time and controlling said power level to said at least one induction coil so that said temperature of said material in said material container obtains a certain temperature in a time period that is equal to said target cycle time, said target cycle time can be a set or adjustable value. 12. The method as defined in claim 1, including the step of depositing said material in a forming or casting machine after said material in said material container has reached a desired temperature, solids fraction, and combinations thereof.
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