Abstract:
An electromagnetic induction heat device to heat a first metal mineral stone and a second mineral stone to form a melting mixture liquid without stifling. The device keeps a temperature of the melting mixture liquid between solidus and liquidus of binary alloy phase diagram of the first and second metal mineral stone, then an alloy with solid state precipitates from said melting mixture liquid.

Description:
FIELD OF THE INVENTION 
     The present invention relates generally to a method and apparatus for manufacturing alloy, and particularly to a method and apparatus for manufacturing high-purity alloy. 
     BACKGROUND OF THE INVENTION 
     As the new products of the photo-electricity, semiconductor and energy are developed, the material&#39;s requirement is from the traditional alloy of steel or aluminum alloy to a new type&#39;s alloy, which is like the semiconductor&#39;s material of GaN, GaAs or CuInSe 2 . The composition of the traditional alloy has a specific range. Furthermore, the impurity&#39;s content of the higher quality&#39;s traditional alloy must be limited. Hence, the metallurgical technology or smelting method with tradition, for example, vacuum induction melting, utilizes online analysis to adjust each element of the composition in alloy melting&#39;s liquid state. Nevertheless, the precision of above online analysis&#39;s control just attains to ±0.1%. In cooling and solidify process, either much or little segregation still appear according to different alloys&#39; natural phase diagrams. Accordingly, the micro-structure of the material has much precipitation phase or segregation so the material is not uniform, but this phenomenon is accepted by traditional materials. 
     However, this phenomenon is not accepted by the new materials of the solar cell, magnetic recording and semiconductor. The new materials of the solar cell, magnetic recording and semiconductor must have high purity, which not only relates to impurity&#39;s content of the material but also relates to stoichiometry of the material. For these new materials, the off-stoichiometry of the material just has a little error (the precision is less than ±0.1%) and the feature of the materials, for example, resistance coefficient, light&#39;s refractive index, reflecting rate or magnetism is completely different. Hence, these new materials are manufactured by the method of physical vapor deposition or high purity powder metallurgy. Nevertheless, the method of physical vapor deposition or high purity powder metallurgy is too expensive. 
     The mixture alloy usually results uniform property from the big different melting of the different metal material, so this invention provides a method and apparatus for manufacturing high-purity alloy. The method and apparatus for manufacturing high-purity alloy can economize the cost of the method of physical vapor deposition or high purity powder metallurgy. Furthermore, this invention can get high purity alloy, which is used for the material of the solar cell, magnetic recording and semiconductor. 
     SUMMARY OF THE INVENTION 
     An objective of the present invention is to provide a method and apparatus for manufacturing high-purity alloy that economize the cost of the method of physical vapor deposition or high purity powder metallurgy and high purity alloy is got. 
     Another objective of the present invention is to provide a method and apparatus for manufacturing high-purity alloy, which can get high purity alloy, which is used for the material of the solar cell, magnetic recording and semiconductor. 
     In order to achieve the objectives described above, the present invention provides a method and apparatus for manufacturing high-purity alloy. The method and apparatus of the present invention disclose the electromagnetic induction heat device to heat a first metal mineral stone and a second mineral stone to form a melting mixture liquid without stirring. Keep a temperature of the melting mixture liquid between solidus and liquidus of binary alloy phase diagram of the first and second metal mineral stone, then an alloy with solid state precipitates from said melting mixture liquid. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  shows a flowchart according to a preferred embodiment of the present invention; 
         FIG. 2A  shows a schematic diagram of the apparatus in the steps S 10  and S 11  according to a preferred embodiment of the present invention; 
         FIG. 2B  shows a schematic diagram of the apparatus in the step S 12  according to a preferred embodiment of the present invention; 
         FIG. 2C  shows a schematic diagram of the apparatus in the step S 13  according to a preferred embodiment of the present invention; 
         FIG. 2D  shows a schematic diagram of the apparatus in the step S 14  according to a preferred embodiment of the present invention; 
         FIG. 2E  shows a schematic diagram of the apparatus in the step S 15  according to a preferred embodiment of the present invention; 
         FIG. 2F  shows a schematic diagram of the apparatus in the step S 16  according to a preferred embodiment of the present invention; and 
         FIG. 3  shows a schematic diagram of the apparatus according to another preferred embodiment of the present invention. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Refer to  FIG. 1  and  FIG. 2A  show a flowchart and a schematic diagram of the apparatus in the steps S 10  and S 11  according to a preferred embodiment of the present invention. As shown in the figure, the present invention provides a method and apparatus for manufacturing high-purity alloy. The apparatus comprises a vacuum chamber  10  with a material feeding tube  104 , a first crucible  12 , an electromagnetic induction heat device  14  and a second crucible  16 . By using the apparatus, the step S 10  is executed for putting a first metal mineral stone  11  into the first crucible  12 , where the first metal mineral stone  11  is a metal bulk, and the material of the first crucible  12  is a ceramic material with melting point greater than that of the feeding metal material. Then, gas an inert gas  13  into the vacuum chamber  10 , and put the first crucible  12  with the first metal mineral stone  11  into the vacuum chamber  10 . Before gassing the inert gas  13  into the vacuum chamber  10 , the inert gas  13  is first used to purge the vacuum chamber  10 . Finally, seal the vacuum chamber  10 , and let the inert gas  13  be maintained in the vacuum chamber  10 . After the first crucible  11  loaded with the first metal mineral stone  11  is put into the vacuum chamber  10 , the step S 11  is executed for setting the first crucible  12  in the electromagnetic induction heat device  14 , which is used for heating the first metal mineral stone  11  in the first crucible  12  to be totally melt and become a melting liquid  110 . The electromagnetic induction heat device  14  can adjust heat temperature and melt the metal mineral stone  11 . Furthermore, the metal mineral stone  11  and the melting liquid  110  are induced and dispersed uniformly by the electromagnetic induction heat device  14 , so as to not need stirring process. 
       FIG. 2B  shows a schematic diagram of the apparatus in the step S 12  according to a preferred embodiment of the present invention. As shown in the figure, after the metal mineral stone  11  in the first crucible  12  is melt into the melting liquid  110 , the step S 12  is executed for adding a second metal mineral stone  15  slowly to the melting liquid  110  in the first crucible  12  by using the material feeding tube  104 . Besides, the electromagnetic induction heat device  14  is used for heating the first crucible  12  with the melting liquid  110  and the second metal mineral stone  15  so that the temperature of the melting liquid  110  is heated above the melting point of the first and second metal mineral stone. Thereby, the second metal mineral stone  15  are melt completely in the melting liquid  110  and a melting mixture liquid  112  is uniformly produced by the electromagnetic induction heat device  14 . The composition ratio of the final high-purity solid-state alloy without other phases precipitated from the first metal mineral stone and second metal mineral stone is in accordance with the designer. 
       FIG. 2C  shows a schematic diagram of the apparatus in the step S 13  according to a preferred embodiment of the present invention. As shown in the figure, when the melting mixture liquid  112  is produced, the step S 13  is executed for controlling the temperature of the electromagnetic induction heat device  14  to fall within a temperature range. Thereby, the temperature of the melting mixture liquid  112  will be within the temperature range, which is above the solidification temperature and below the liquification temperature of the melting mixture liquid  112 . Thereby, according to the present invention, it is not necessary to adopt accurate and costly temperature control systems. In addition, the precipitated quantity (weight) of an alloy  114  depends on the composition of the melting liquid and the precipitation temperature. In general, within the broad ranges of composition and temperature conditions according to the present invention, the higher the proportion of the first metal mineral stone and the lower the precipitation temperature, the more the precipitated quantity of the alloy  114 . The exact precipitated quantity (weight) can be calculated according to the level rule of phase diagram in physical metallurgy. 
       FIG. 2D  shows a schematic diagram of the apparatus in the step S 14  according to a preferred embodiment of the present invention. As shown in the figure, the alloy  114  in solid-state is precipitated from the melting liquid  112 . The first metal mineral stone composition of the alloy  114  is greater than that in the melting liquid  112 . With the progress of precipitation reaction, according to the law of conservation of mass, the composition of a residual liquid  116  still have metal-rich. The density of the first metal mineral stone is much greater than that of the second metal mineral stone, therefore, the alloy  114  will sink at the bottom of the first crucible  12 . After the melting liquid  112  precipitated the alloy  114 , the step S 14  is executed for separating the residual liquid  116  in the first crucible  12  from the alloy  114  suck at the bottom of the first crucible  12  by pouring the residual liquid  116  in the first crucible  12  into the second crucible  16 . In order to pour the residual liquid  116  in the first crucible  12  into the second crucible  16  easily, an inclinable base  19  is adapted in the vacuum chamber  10  with the first crucible  12  and the electromagnetic induction heat device  14  set thereon. When the base  19  inclines the first crucible  12  and the electromagnetic induction heat device  14  incline with the inclinable base  19 , and the residual liquid  116  will be poured into the second crucible  16 . Finally, the alloy  114  will be left at the bottom of the first crucible  12 . 
       FIG. 2E  shows a schematic diagram of the apparatus in the step S 15  according to a preferred embodiment of the present invention. As shown in the figure, the step S 15  is executed. Draw out the first crucible  12  from the electromagnetic induction heat device  14 , and cool the first crucible  12  loaded with the alloy  114 . In or to draw out the first crucible  12  from the electromagnetic induction heat device  14  conveniently, a hoist mechanism  17  is further adapted in the vacuum chamber  10  and deposes the bottom of the chilled plate for moving the first crucible  12  up and down to leave the electromagnetic induction heat device  14 . The hoist mechanism  17  includes a plurality of twisted ropes  171 , which is fixed on a curved fringe  121  of the first crucible  12 . Thereby, the hoist mechanism  17  can draw out the first crucible  12  from the electromagnetic induction heat device  14 . In addition, in order to secure the connection between the hoist mechanism  17  and the first crucible  12 , a curved fringe  121  is adapted at the periphery of the opening of the first crucible  12 . A hanging hook (not shown in the figure) is adapted on one end of the plurality of twisted ropes  171  of the hoist mechanism  17 , respectively. Thereby, the hanging hooks are hooked on the curved fringe  121  of the first crucible  12 . Thus, the connection between the hoist mechanism  17  and the first crucible  12  is secured. Then, the hoist mechanism  17  can move the first crucible  12  from the heat device  14  for putting the residual liquid  116  to the second crucible  16 . 
     Another significant technological breakthrough of the present invention is to recycle the residual liquid, and thereby a method and apparatus for continuously manufacturing high-purity alloy is developed.  FIG. 2F  shows a schematic diagram of the apparatus in the step S 16  according to a preferred embodiment of the present invention. As shown in the figure, after the first crucible  12  is drawn out from the electromagnetic induction heat device  14 , the step S 16  is executed for putting the second crucible  16  loaded with the residual liquid  116  into the heating device  14  by using the hoist mechanism  17 . Then, the steps from S 10  through S 16  are executed repeatedly for continuously manufacturing the high-purity alloy  114 . The first and the second crucibles  12 ,  16  are used alternately owing to continuous manufacturing. 
     While manufacturing continuously, the second and thereafter manufacturing cycles differ from the first manufacturing cycle in that, in the second and thereafter manufacturing cycles, in order to increase productivity of the alloy  114 , the amount of added the second metal mineral stone can be increased. 
       FIG. 3  shows a schematic diagram of the apparatus according to another preferred embodiment of the present invention. As shown in the figure, the present invention provides an apparatus for manufacturing a high-purity alloy and comprising a vacuum chamber  10 , a first crucible  12 , an electromagnetic induction heat device  14 , a second crucible  16 , a hoist mechanism  17 , a water-cooled copper base  100  with recycling cooling water, and a material feeding tube  104 . The vacuum chamber  10  according to the present preferred embodiment is divided into a precipitation chamber  101  and a crucible in/out chamber  103 . One or more isolation valves  102  are adapted between the precipitation chamber  101  and the crucible in/out chamber  103 , so that the precipitation chamber  101  can be maintain in vacuum or in the inert gas no matter separation or crucible in/out is undergoing. 
     The first crucible  12 , the electromagnetic induction heat device  14 , the hoist mechanism  17 , the water-cooled copper base  100 , and the material feeding tube  104  are set in the precipitation chamber  101  of the vacuum chamber  10 . The first crucible is set on the electromagnetic induction heat device  14 . The hoist mechanism  17  is also set on top of precipitation chamber  101  of the vacuum chamber  10 . The water-cooled copper base  100  is set on one side of the first crucible  12 . The material feeding tube  104  penetrates the vacuum chamber  10 . 
     According to the present invention, place a first metal mineral stone to the first crucible  12  on the crucible in/out chamber  103  of the vacuum chamber  10 , and gas an inert gas to the vacuum chamber  10 . Use the hoist mechanism  17  to put the first crucible  12  loaded with the first metal mineral stone to the precipitation chamber  101  filled with the inert gas and into the electromagnetic induction heat device  14 . The electromagnetic induction heat device  14  heats the first crucible  12  loaded with the first metal mineral stone, melts the first metal mineral stone to a melting liquid. 
     Then, a second metal mineral stone via the feeding tube  104  penetrating the vacuum chamber  10 , the second metal mineral stone is added into the first crucible  12  loaded with the melting liquid. By using the electromagnetic induction heat device  14 , the first crucible  12  loaded with the second metal mineral stone and the melting liquid. Next, control the temperate of the electromagnetic induction heat device  14  to fall within a temperature range for the melting mixture liquid to precipitate an alloy in the solid-state. Then, separate the residual liquid in the first crucible  12  from the precipitated the alloy. 
     And, place a first metal mineral stone in the second crucible  16  and put it to the precipitation chamber  101  of the vacuum chamber  10 . Use the hoist mechanism  17 , which is capable of inclining, to put the first crucible  12  loaded with residual liquid to the second crucible  18 , and put the first crucible  12  on the water-cooled copper base  100  in the precipitation chamber  101 . The water-cooled copper base  100  cools the alloy in the first crucible  12 . After cooling, use the hoist mechanism  17  to pick the first crucible  12  out, and take the alloy from the first crucible  12 . The water-cooled copper base  100  is adapted in the precipitation chamber  101 . Because the activity of the alloy is very high, it tends to react with oxygen or even ignite, deteriorating its characteristics and producing dangers, it is necessary to cool sufficiently before drawing out from the precipitation chamber  101  in vacuum or filled with the inert gas. 
     In mass production, for example, smelt above hundreds of kilograms or tons, the cooling rate of nature cooling is insufficient, and thus limiting the production efficiency. Thereby, the water-cooled copper base is equipped in the precipitation chamber  101 . By taking advantage of the excellent heat-sinking characteristic of copper, the first crucible loaded with the high-purity alloy can be quenched rapidly. 
     To sum up, the present invention provides a method and apparatus for manufacturing a high-purity alloy, which can be used for manufacturing a high-purity alloy without the need of adopting the method of physical vapor deposition or high purity powder metallurgy, so as to economize the cost of the method of physical vapor deposition or high purity powder metallurgy and the high-purity alloy is got. In addition, the residual liquid after precipitation reaction can be recycled and the high-purity alloy can be manufactured continuously. 
     Accordingly, the present invention conforms to the legal requirements owing to its novelty, non-obviousness, and utility. However, the foregoing description is only a preferred embodiment of the present invention, not used to limit the scope and range of the present invention. Those equivalent changes or modifications made according to the shape, structure, feature, or spirit described in the claims of the present invention is included in the appended claims of the present invention.