# Patent

## Title
Method and apparatus for semi-solid material processing

## Abstract

A method of forming a material includes the steps of: vibrating a molten material at an ultrasonic frequency while cooling the material to a semi-solid state to form non-dendritic grains therein; forming the semi-solid material into a desired shape; and cooling the material to a solid state. The method makes semi-solid castings directly from molten materials (usually a metal), produces grain size usually in the range of smaller than 50 μm, and can be easily retrofitted into existing conventional forming machine.

## Background
This application is a continuation of, and claims a benefit of priority under 35 U.S.C. 120 from patent application U.S. Ser. No. 10/871,180, filed Jun. 17, 2004 now U.S. Pat. No. 7,216,690 the entire contents of which are hereby expressly incorporated herein by reference for all purposes.


The United States Government has rights in this invention pursuant to contract no. DE-AC05-00OR22725 between the United States Department of Energy and UT-Battelle, LLC.


FIELD OF THE INVENTION
The present invention relates to semi-solid processing of materials, and more particularly to semi-solid processing of materials using ultrasonic vibration to form non-dendritic grains therein.
BACKGROUND OF THE INVENTION
Thixocasting and rheocasting are widely used industrial process for high volume production of SSM components. Problems associated with such processing include: costly and complex feed (process) material preparation (thixocasting); material loss (thixocasting), agglomeration, and grain coarsening during process material preparation (rheocasting), causing large grain size in the product; costly equipment to hold semi-solid slurry process material at constant temperatures (rheocasting); low solid fractions of process materials (rheocasting); and oxidation of process material during processing.
OBJECTS OF THE INVENTION
Accordingly, objects of the present invention include: methods of forming a semi-solid structure directly from molten metal prior to metal forming (e.g., casting, forging) with desired fraction solid, producing grain size much smaller than thixocasting and rheocasting, reducing or eliminating process run-around, and reusing process run-around if there is any. Further and other objects of the present invention will become apparent from the description contained herein.
SUMMARY OF THE INVENTION
In accordance with one aspect of the present invention, the foregoing and other objects are achieved by a method of forming a material that includes the steps of: vibrating a molten material at an ultrasonic frequency while cooling the material to a semi-solid state to form non-dendritic grains therein; forming the semi-solid material into a desired shape; and cooling the material to a solid state.
In accordance with another aspect of the present invention, a machine for forming a material includes means for vibrating a molten material at an ultrasonic frequency while cooling the material to a semi-solid state to form non-dendritic grains therein.
In accordance with another aspect of the present invention, a article includes a semi-solid-processed body characterized by globular, non-dendritic grains having an average diameter of no more than 1000 μm.



BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic cutaway side view of an ultrasonic processor in accordance with the present invention.
FIG. 2 illustrates an embodiment of the present invention using a turntable conveyer.
FIG. 3 illustrates an embodiment of the present invention using a chain-type conveyer.
FIGS. 4(a)-4(e) illustrate an embodiment of the present invention wherein a forming machine (die caster) is modified to incorporate an ultrasonic processor directly into its mechanism.
FIG. 5 is a photomicrograph of aluminum A356 alloy cooled in a copper mold with no ultrasonic vibration.
FIG. 6 is a photomicrograph of aluminum A356 alloy cooled in a copper mold with ultrasonic vibration in accordance with the present invention.
Equivalent components are assigned the same reference numerals throughout the drawings.



For a better understanding of the present invention, together with other and further objects, advantages and capabilities thereof, reference is made to the following disclosure and appended claims in connection with the above-described drawings.
DETAILED DESCRIPTION OF THE INVENTION
The present invention is carried out by “ultrasonic processing”, which comprises vibrating molten process material (usually a metal) at an ultrasonic frequency as it cools to a semi-solid state in order to form non-dendritic, (i.e., globular-shaped, rounded), ideally spherical) grains having an average diameter of no more than 1000 μm, preferably no more than 100 μm, more preferably no more than 50 μm, most preferably no more than 1 μm. Such grain structure is most beneficial for semi-solid forming processes. Ultrasonic processing in accordance with the present invention generally avoids formation of large and/or dendritic grains in the process material.
In accordance with the present invention, vibration at an ultrasonic frequency is operably applied at a frequency in the range of 1 kHz to 106 kHz, preferably in the range of 15 kHz to 25 kHz, and at a power intensity in the range of 1 W to 106 W, preferably in the range of 500 to 1000 w. The duration of ultrasonic processing is in the range of 1 millisecond to one hour depending on the type and volume of metal being processed. Once the beneficial results of ultrasonic processing are achieved, continued subjection of the process material is not deleterious; therefore duration is not considered to be a critical parameter.
Referring to FIG. 1, an example of a basic apparatus for carrying out the present invention comprises an ultrasonic processor 10. A cylindrical sleeve 12 contains molten and/or semi-solid process material 14. A ram (piston) 16 is inserted into the lower end 18 of the sleeve 12. An ultrasonic transducer 20 produces ultrasonic vibration that is transmitted to the process material 14 via an ultrasonic radiator (horn) 22. Process material 14 is transferred into and out of the sleeve 12 through the upper end 24 thereof.
In operation, molten process material 14 is transferred into the ultrasonic processor 10 at a temperature of at least above the liquidus temperature of the process material 14. The ultrasonic transducer 20 produces ultrasonic vibration that is transmitted to the process material 14 via an ultrasonic radiator (horn) 22. The process material 14 cools to the semi-solid state while being exposed to ultrasonic vibration. The ultrasonic vibration promotes nucleation and the formation of predominantly non-dendritic, generally globular grains. The ram 16 then pushes the semi-solid process material 14 as a slug (billet) out of the sleeve 12 through the upper end 24 thereof to transfer the semi-solid process material 14 to a forming machine. The non-dendritic, generally spherical grains persist throughout the forming process.
Some embodiments of the present invention include a conveyer interposed in the process between a heater that melts the process material and a forming machine that forms the process material. Any conveyer that can support at least one ultrasonic processor 10 is contemplated to be suitable for application to the present invention. It is preferred that a conveyer support a plurality of ultrasonic processors 10. Examples of conveyers are set forth below to show the general principle of the present invention.
Referring to FIG. 2, a conveyer 40 comprises a turntable 42 that supports a plurality of ultrasonic processors 10. The turntable 42 having six positions A-F is indexed so that an ultrasonic processor 10 is aligned with the furnace 44 in position A and another ultrasonic processor 10 is aligned with the forming machine 46 in position F. As the turntable 42 rotates clockwise (in the direction of the arrow), molten process material 14 is transferred from the furnace 44 to the ultrasonic processors 10 while semi-solid slugs of process material 14 are transferred to the forming machine 46. As the ultrasonic processors 10 rotate through positions B, C, D, and E, the process material 14 is cooled to a semi-solid state while undergoing exposure to ultrasonic vibration, causing the formation of predominantly non-dendritic, generally spherical grains in the process material 14, which persist through the forming process.
FIG. 3 illustrates an embodiment wherein a conveyer 50 comprises a belt or chain 52 with ultrasonic processors 10. The furnace 44 and forming machine 46 can be at any desired location, and the belt or chain 52 can be in any desired configuration.
In other embodiments of the present invention, the forming machine is modified to incorporate an ultrasonic processor directly into its mechanism. Molten process material is transferred directly to the forming machine and the ultrasonic processing takes place therein.
FIGS. 4(a)-4(e) illustrate an embodiment of the present invention wherein a die-casting machine 60 is modified to incorporate an ultrasonic processor 10 directly into its shot-sleeve 64.
In FIG. 4(a) an ultrasonic processor 10 is inserted into an opening 68 in the shot-sleeve 64 just ahead of the injection ram 66. Molten process material 14 is transferred into the ultrasonic processor 10 where it is processed in accordance with the present invention.
In FIG. 4(b) the ultrasonic processor 10 retracts downwardly sufficiently to allow the injection ram 66 to pass thereover. In FIG. 4(c) the ultrasonic processor 10 and the injection ram 66 advance toward the casting die 62 sufficiently to close the opening 68, which has an extension 70 therein to accommodate advance of the ultrasonic processor 10.
In FIG. 4(d), ultrasonic processing having been completed, the ram 16 of the ultrasonic processor 10 advances and forces the process material 14 into the shot-sleeve 64. In FIG. 4(e) the injection ram 66 advances and forces the process material 14 into the die 62.
Within the scope of the present invention, an ultrasonic processor can be brought into operable communication with process material in any configuration. For example, an ultrasonic processor can be attached to a vessel wall, or can be inserted directly into the process material.
EXAMPLE I
An acoustic radiator was attached to the bottom of a copper mold. Aluminum alloy A356 was melted and poured into the mold and allowed to cool to a solid state with no ultrasonic vibration. The microstructure of the resultant solid alloy is shown in FIG. 5. The grains are observed to be large (1-10 mm) and dendritic. The microstructure is deleterious to semi-solid processing, especially forming.
EXAMPLE II
An acoustic radiator was attached to the bottom of a copper mold. Aluminum alloy A356 was melted and poured into the mold and allowed to cool to a solid state while being exposed to ultrasonic vibration in accordance with the present invention. The microstructure of the resultant solid alloy is shown in FIG. 6. The grains are observed to be smaller than 50 μm in diameter and globular—ideal for semi-solid processing.
Utilization of the present invention provides the advantage of resource savings because less capital investment (equipment, etc.) and energy are required to carry out the present invention than that required by conventional technology. Moreover, the present invention allows for the reuse of the process run-around (5% of the feedstock metals). Moreover, less oxide waste is produced because there is less exposure of process material to air.
Moreover, the present invention enables a large process window for semi-solid processing because the metal is held in containers throughout the processing shown in FIG. 4. The process material can be injected into a forming machine at any desired solid fraction.
Although the present invention is generally used to process metallic materials, other materials can be processed in accordance with the present invention, for example, polymers, ceramics, and composite materials.
While there has been shown and described what are at present considered the preferred embodiments of the present invention, it will be obvious to those skilled in the art that various changes and modifications can be prepared therein without departing from the scope of the inventions defined by the appended claims.

## Claims

1. A method, comprising:
transferring molten process material directly to a die-casting machine including a shot-sleeve; and
ultrasonic processing molten process material in the shot sleeve,
wherein transferring includes inserting an ultrasonic processor into an opening in the shot-sleeve just ahead of an injection ram, retracting the ultrasonic processor into the opening in the shot-sleeve just ahead of the injection ram, and advancing the ultrasonic processor and the injection ram toward a casting die sufficiently to close the opening, the opening having an extension therein to accommodate advance of the ultrasonic processor.

2. The method of claim 1, further comprising advancing a ram of the ultrasonic processor to force molten process material into the shot-sleeve.

3. The method of claim 2, further comprising advancing the injection ram to force molten process material into the casting die.

4. The method of claim 1, wherein ultrasonic processing molten process material in the shot sleeve is at a frequency in the range of from 15 kHz to 25 kHz and at a power intensity in the range of from 500 to 1000 W.

5. A machine, comprising:
a die-casting machine including a shot-sleeve,
wherein an ultrasonic processor is incorporated directly into the shot-sleeve,
wherein the shot-sleeve defines an opening, the opening just ahead of an injection ram when the injection ram is retracted, and
wherein the ultrasonic processor and the injection ram are advancable toward a casting die sufficiently to close the opening, the opening having an extension therein to accommodate advance of the ultrasonic processor.

6. The machine of claim 5, wherein the ultrasonic processor operates at a frequency in the range of from 15 kHz to 25 kHz and at a power intensity in the range of from 500 to 1000 W.