Modernization of casting magnetodynamic equipment

Transcription

1 Modernization of asting magnetodynami equipment V Dubodelov, V Fikssen, M Slazhniev, M Goryuk, Iu Skorobagatko, E Seredenko, O Yashhenko To ite this version: V Dubodelov, V Fikssen, M Slazhniev, M Goryuk, Iu Skorobagatko, et al.. Modernization of asting magnetodynami equipment. 8th International Conferene on Eletromagneti Proessing of Materials, Ot 2015, Cannes, Frane. EPM2015. <hal > HAL Id: hal Submitted on 22 Jun 2016 HAL is a multi-disiplinary open aess arhive for the deposit and dissemination of sientifi researh douments, whether they are published or not. The douments may ome from teahing and researh institutions in Frane or abroad, or from publi or private researh enters. L arhive ouverte pluridisiplinaire HAL, est destinée au dépôt et à la diffusion de douments sientifiques de niveau reherhe, publiés ou non, émanant des établissements d enseignement et de reherhe français ou étrangers, des laboratoires publis ou privés.

2 Modernization of asting magnetodynami equipment V. Dubodelov, V. Fikssen, M. Slazhniev, M. Goryuk, Iu. Skorobagatko, E. Seredenko, O. Yashhenko MHD Department of Physio-Tehnologial Institute of Metals and Alloys of National Aademy of Sienes of Ukraine (PTIMA NASU), Kyiv, Ukraine Corresponding author: (V. Dubodelov) Abstrat During last 10 years in the PTIMA NASU there is made the all-round modernization of magnetodynami equipment for manufaturing of ast prodution from aluminium alloys, ast iron and steel. Suh modernization had inluded both widening of funtionality of magnetodynami installations and development of onomitant MHD-tehnologies for preparation and ing of high-quality alloys in the foundry, metallurgy and mahine-building. Introdution Now the requirements to quality of ast prodution beome tougher onstantly. It is appeared in neessity to provide: - the high leanness of alloys and wares from them from gases, non-metallis; - absene of asting defets; - maximal approahing of asting (ingot) to geometry of final ware; - advane of quality of alloys and astings (rise of physial, mehanial, tehnologial, operating and speial properties); - providing of automation; - rise of produtivity; - improvement of eology. Developed in the PTIMA NASU magnetodynami devies for preparation and ing of alloys are used widely for manufaturing of astings at foundry shops, metallurgial plants and mahine-building enterprises. In the last 10 years, there is realized modernization of suh equipment. Results As it is well known, magnetodynami devies (installations & mixers-bathers) ombines in one aggregate both ution hannel furnae and tromagneti pump [1, 2]. In omparison with similar trotehnologial equipments, it provides ependent ontrol of al state of melt due to regulated ution heating and guided tromagneti stirring. At that, there are realized the proessing of liquid ferrous and non-ferrous alloys, and also their ontrolled tromagneti ing into sand molds, hill molds (inluding die astings mahines), rystallizers, pans. Eletri urrent in melt in the magnetodynami devie is uted due to Ohms law [1]: j Е В, А/m 2, (1) where j tri urrent density, А/m 2 ; tri ondution, S; E tri field intensity, V/m; veloity of melt, m/se; B magneti ution, T. Melt heating in the magnetodynami equipments is provided aordingly to Joule law at arrying of tri urrent uted in the melt (in the hannels) [1]: 2 q j Е В (or as salar equation I R ), J, (2) where q и heat generation in the melt, J; I tri urrent, А; R trial resistane, Ohm; time, se. It is usual for any ution hannel devie. But, the priniple feature of magnetodynami devies is itional tromagnet [1]. It reates the internal alternating magneti field on the part of the hannel (so alled working area). At superposition of this field with tri urrent in melt, there is generated volume tromagneti fore [1]: V j B d V BIL F Re (or as salar equation F os ), N/m 3, (3) where V volume of working area, m 3 ; L length of working area, m; phase-shift angle between tri urrent and magneti field. V

3 This fore provides the melt moving. At that, modes (diretions and intensities) of suh moving determine by tri parameters of utor and tromagnet. Pratially, it is both irulation between ruible and hannel (in fat stirring) and tromagneti ing of melt at set al and hydrodynami terms. Generated in the magnetodynami devies tromagneti pressure is determined as [1]: BIL р j B L os α (or as salar equation os S p ), Pa, (4) where S square of working area, m 2. One of main feature of magnetodynami aggregates is ing of melt diretly from heating zone ution hannel. It allows realizing the developed in the MHD Department of PTIMA NASU tehnology of differentiated heating of liquid metal [3, 4]. It onsists in holding of melt in ruible of the magnetodynami devie at low temperature and overheating up to ing temperature only ed of melt during its moving through ution hannel. In general, average overheating of melt between hannel and ruible of the magnetodynami aggregate makes [3, 4]: Т aver. stat k ir P, С, (5) где, aordingly trial and al effiieny of magnetodynami devie; k part of power released ir in hannel in omparison with all power released in melt volume (for magnetodynami devies k с = 0,7-0,8); Р utor power, W; с heating apaity of melt, J/(kgС); mass flow rate of liquid metal at its irulation between hannel and ruible, kg/se. At ing, summary overheating of melt in the magnetodynami aggregate makes:, С, (6) Т Т Т aver. stat aver. where average overheating of ed diretly at its poring from the devie, С. It is: Т aver. Т aver. с k Р т М, С, (7) where kg/se; М mass of melt in the ution hannel of the aggregate, kg; mass flow rate of melt at ing, т mass of ed, kg. So, equation (6) transforms to: Т с k Р 1 ir М т, С (8) For optimum onsumption of power resoures at dosage ing the ratio of parameters should be the next: М t t M t Р 0 ir where М weight of metal in the aggregate, kg; t temperature of metal in the devie, С; yle, (9) duration of between ing of two s of metal, se; mass flow of metal at ing, kg/se; ing time of one, se; t set ing temperature, С; М weight of metal portion, ed into the aggregate, kg; t value of an neessary overheating of melt in the magnetodynami aggregate (differene between the set ing temperature of metal and temperature of metal, ed into the devie: ( yle ), se. t t t ), С; yle time yle for one ing For ontinuous proesses the ratio (9) should be hanged. So, in ase of ontinuous ing of molten metal into the magnetodynami aggregate without stopping of dosage ing of melt from the devie, the ratio (9) is the following:

4 yle 0, М t t Р t ir yle 0 (10) Where mass flow rate of melt ing ontinuously into the aggregate, kg/se. At ontinuous ing of metal with periodi ing of melt into the magnetodynami devie, the ratio (9) hanges to: M t t M 0 Р t ast ast ast, (11) the summary time, during whih there is only ing of melt s from the devie in the reeiving de- where ast vie, se; the summary time, during whih there is synhronous ing of metal from the magnetodynami ast aggregate and ing of new portion of melt into the devie, se. For fully ontinuous proesses (ontinuous ing of melt into the aggregate and ontinuous ing of melt from the devie), the ratio (9) transforms into the following: t t 0 Р (12) Using ratios (9) (12), it is possible to optimize material & power onsumptions and to provide high quality of prodution at asting proesses with appliation of magnetodynami equipment for preparation and ing of alloys. There is developed multifuntion asting MHD-omplex for manufaturing of high-quality aluminium astings. The omplex is able to work effetively in different being asting tehnologies. The main devie of the omplex is the magnetodynami mixer-bather (Fig. 1) that provides advaned tehnial parameters (ution heating, tromagneti pressure, and mass flow rate at tromagneti stirring & ing of aluminium melt). Fig. 1: Magnetodynami mixer-bather for preparation and ing of aluminium alloys Mixer-bather operates at supply of three-phase AC by frequeny Hz and voltage 220/380 V. The omplex provides the substantial improvement of struture and inreasing of properties of aluminium alloys and astings due to: - high-speed dissolution of alloying itions and modifiers in melt, homogenizations of hemial omposition and temperatures of liquid aluminium alloys at ontrolled tromagneti stirring; - al & fored proessing of melt [5], inluding possible ombination of tromagneti influene and MHD-effets with other high-energy ations, modulation of tromagneti fore [6] and reation of ontrolled pinh-effet in the ution hannel and working area of magnetodynami mixer-bather [7]; - realization of high effiieny refining of alloys (by argon blowing redution of hydrogen ontent to 0,10-0,05 m 3 /100 g of metal at the simultaneous eonomy to 50% argon and reduing on 30% time of treatment in omparison with existing tehnologies, by filtration with passing of tri urrent in melt removal to 80% non-metallis) [8]; - dereasing dosage error at tromagneti ing of metal no more than 1-2% from mass of [9]; - redution of minimum mass flow rate of melt at ing to 0.3 kg/se and inreasing of maximum mass flow rate up to 10 kg/se; - realization of asting tehnologial proesses under low ontrolled tromagneti pressure, inluding using of lost foam models and dispersed non-solidifying gating system [10, 11]. Appliation of developed asting omplex and magnetodynami mixer-bather provides manufaturing of high-quality aluminium alloys (hypoeuteti & hypereuteti silumins, high-strength Al Cu alloys) and astings with improved struture and inreased mehanial properties. In partiular, al & fored proessing of liquid alloys A356 & A390 in the MHD-mixer-bather reates the onditions for break-up of miroinhomogeneities (aused by negative metallurgial heredity) in the melt. It provides inreasing to 2-4 times of elongation of iated alloys [5]. Further progress of magnetodynami equipment for aluminium alloys onsists in providing of higher tromagneti pressure for new asting tehnologies [12]. There is realized modernization of magnetodynami devies for overheating and ing of ast iron and steel (Fig. 2).

5 Fig. 2: Magnetodynami mixer-bather for overheating and ing of ast iron and steel So, it is developed the analog system based on using thyristor regulator of tri urrent for operation ontrol of magnetodynami mixer-bather for ast iron. Comparing to similar well-known ontrol systems for ution hannel furnae, using suh system for magnetodynami devies has some features. Usually thyristor distorts the sinusoidal urrent whih is important for generating of substantial tromagneti pressure for different modes of stirring and ing of melt by magnetodynami mixer-bather. This task was solved suessfully, and suh aggregate with new ontrol system was applied in ustry at manufaturing of astings from ast iron. It provides the eonomy to 20% of energy in omparison to using of ontrol system on the base of autotransformers. In omparison of onventional ladle ing, using of tromagneti ing of ast iron and steel by MHD-mixerbather at prodution of astings and ingots allowed to stabilize the al and hydrodynami terms of mould filling and further forming of asting, to derease the spoilage, to provide the improvement of ast struture of and inrease of basi mehanial properties of alloys and astings on 10-15% [13]. Guided tromagneti stirring of melt in the magnetodynami mixer-bather provides melt homogenization on temperature and hemial omposition, neessary al and hydrodynami terms for dissolution and distributing in melt volume of alloying and modifying itions [14]. Lately there is suessful appliation of suh aggregate as magnetodynami tundish at ontinuous asting of steel [14]. Conlusion Modernization of magnetodynami devies for foundry and metallurgy has provided to improve the quality of manufatured ast prodution, to inrease the tehnial and eonomi ies of proess, to reate the neessary prerequisites for further fundamental and applied researhes and tehnologial progress. Referenes [1] V. Polishhuk, R. Horn, M. Tsin, V. Dubodelov, V. Pogorsky, V. Trefniak (1989), Magnetodynami pumps for liquid metals, Kyiv, Naukova dumka (in Russian) [2] V. Dubodelov (1994), International Symposium on Eletromagneti Proessing of Materials EPM-1994, Tokyo (Japan), [3] V. Dubodelov, M. Tsin, V. Pogorsky, A. Gorshkov (1997), International Congress on Eletromagneti Proessing of Materials EPM-1997, Paris-La-Defense (Frane), Vol. 2, [4] Dubodelov V., Pogorsky V., Goryuk M. (2002), 5 th International PAMIR Conferene on Fundamental and Applied MHD, Ramatuelle (Frane), Vol. 2, II-171 II-176 [5] V. Dubodelov, V. Fikssen, M. Slazhniev, M. Goryuk, I. Skorobagatko, A. Berezina, T. Monastyrska, O. Davydenko, V. Spuskanyuk (2012) Magnetohydrodynamis, 2 (48), [6] Dubodelov V.I., Fixsen V.N., Pogorsky V.K., Gorshkov A.O., Slazhnev N.A. (2000), 3 rd International Symposium on Eletromagneti Proessing of Materials EPM-2000, Nagoya (Japan), [7] V.I.Dubodelov, N.A.Slazhnev, V.N.Fixsen, Y.P.Skorobagatko, A.D.Podoltsev, I.N.Kuheryavaya (2006), 5 th International Symposium on Eletromagneti Proessing of Materials EPM-2006, Sendai (Japan), [8] Jung-Moo Lee, Hyun-Suk Sim, V. Dubodelov, V. Fikssen, M. Slazhniev (2010), 12 th International Conferene on Aluminium Alloys (ICAA), Yokohama (Japan), [9] Dubodelov V.I., Slazhniev M.A., Bogdan K.S. (2012), Metallurgy and Mining (Ukraine), 5, (in Russian) [10] V. Dubodelov, O. Shynskyi, V. Fikssen, M. Slazhniev, I. Shynskyi, A. Gorshkov (2009), 6 th International Conferene on Eletromagneti Proessing of Materials EPM-2009, Dresden (Germany), [11] W. Fixsen, L. Ohm, V. Trefnjak (2007), Casting Plant & Tehnology International, 2, [12] Dubodelov V.I., Slazhniev M.A., Moyseev Yu.V., Bogdan K.S., Podoltsev A.D., Goryuk M.S. (2014), 9 th International PAMIR Conferene on Fundamental and Applied MHD, Thermo Aousti and Spae Tehnologies, Riga (Latvia), Vol. 2, [13] V.I. Dubodelov, V.K. Pogorsky, M.S. Goryuk (2011), Key Engineering Materials, Vol. 457, [14] V. Dubodelov, O. Smirnov, V. Pogorsky, M. Goryuk (2006), 5 th International Symposium of Eletromagneti Proessing of Materials EPM-2006, Sendai (Japan),