Ultrasonic Treatment of Light Alloy Melts, Second Edition

346 Pages·2014·8.6 MB·English

by  Georgy I. Eskin

Materials Science
Eskin
Eskin
ULTRASONIC TREATMENT
OF LIGHT ALLOY MELTS
S E C O N D E D I T I O N
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O
“This book, written by two acknowledged experts in the field, presents L
a most extensive overview of ultrasonic processing of light-metal melts, F T
from basic fundamentals to practical applications.”
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—Joseph C. Benedyk, Light Metal Age
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“… a must have in the library of any engineer or scientist who processes S
light metals today. … I found the book to be a catalyzer of innovation.” H O
—Bob Wagstaff, Novelis, Inc., Spokane, Washington, USA
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N

Spawned by growing interest in ultrasonic technology and new developments in A I
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ultrasonic melt processing, the Second Edition of Ultrasonic Treatment of Light
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Alloy Melts discusses use of ultrasonic melt treatment in direct-chill casting,
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shape casting, rapid solidification, zone refining, and more, exploring the effects
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of power ultrasound on melt degassing, filtration, and refinement in aluminum
and magnesium alloys. The fully revised and restructured Second Edition: Y E
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• Contains new, in-depth coverage of composite and nanocomposite
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materials T
• Provides a historical review of the last century of ultrasonic applications E M
to metallurgy
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E
• Emphasizes the fundamentals, mechanisms, and applications of ultrasonic
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melt processing in different light-metal technologies N
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• Features new chapters on ultrasonic grain refinement, refinement of
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primary solid phases, and semi-solid processing of billets with

nondendritic structure
• Includes significant updates reflecting results obtained over the past two
decades on different scales, from laboratory to full-scale industrial E S
D E
implementations
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Complete with many new figures and examples, Ultrasonic Treatment of Light O
I
Alloy Melts, Second Edition delivers a comprehensive treatise on ultrasonic O N
melt processing and cavitation, presenting essential guidelines for practical use N D
and further development of the technology.
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K16821_cover_final.indd 1 7/10/14 11:45 AM

ULTRASONIC
TREATMENT
OF LIGHT
ALLOY MELTS
S E C O N D E D I T I O N
Advances in Metallic Alloys
A series edited by D.G. Eskin, Brunel Centre for Advanced
Solidification Technology (BCAST), Brunel University
Volume 1
Liquid Metal Processing: Applications to Aluminum Alloy Production
I.G. Brodova, P.S. Popel and G.I. Eskin
Volume 2
Iron in Aluminum Alloys: Impurity and Alloying Elment
N.W. Belov, A.A. Aksenov and D.G. Eskin
Volume 3
Magnesium Alloy Containing Rare Earth Metals: Structure and Properties
L.L. Rokhlin
Volume 4
Phase Transformations of Elements Under High Pressure
E.Yu Tonkov and E.G. Ponyatovsky
Volume 5
Titanium Alloys: Russian Aircraft and Aerospace Applications
Valentin N. Moiseyev
Volume 6
Physical Metallurgy of Direct Chill Casting of Aluminum Alloys
Dmitry G. Eskin
Volume 7
Ultrasonic Treatment of Light Alloy Melts, Second Edition
Georgy I. Eskin and Dmitry G. Eskin
AdvAnces in MetAllic Alloys
A series edited by d .G. eskin
ULTRASONIC
TREATMENT
OF LIGHT
ALLOY MELTS
S E C O N D E D I T I O N
Georgy I. Eskin
Dmitry G. Eskin
Boca Raton London New York
CRC Press is an imprint of the
Taylor & Francis Group, an informa business
CRC Press
Taylor & Francis Group
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Boca Raton, FL 33487-2742
© 2015 by Taylor & Francis Group, LLC
CRC Press is an imprint of Taylor & Francis Group, an Informa business
No claim to original U.S. Government works
Version Date: 20140501
International Standard Book Number-13: 978-1-4665-7799-2 (eBook - PDF)
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To Nelly
Beloved wife and mama

Contents
Preface.......................................................................................................................xi
Authors .....................................................................................................................xv
Chapter 1 Historical Overview of Ultrasonic Applications to Metallurgy ...........1
References ..........................................................................................14
Chapter 2 Fundamentals of Ultrasonic Melt Processing ....................................17
2.1 Dynamic Means of Melt Processing .......................................17
2.2 Low-Frequency Vibrations and Ultrasound: Basic
Equations ..............................................................................20
2.3 Propagation of Acoustic Waves in the Melt ............................26
2.4 Acoustic Cavitation in Liquid Metals ......................................32
2.4.1 Cavitation Strength of Liquids ...................................32
2.4.2 Cavity Dynamics ........................................................37
2.4.3 Cavitation Region in Liquids ......................................44
2.5 Acoustic Flows ........................................................................49
2.6 Experimental Studies of Cavitation in Liquid Metals .............55
2.7 Sonoluminescence in Melts .....................................................67
2.8 Accelerated Mixing and Dissolution of Components
in the Melt ................................................................................69
References ..........................................................................................70
Chapter 3 Ultrasonic Degassing..........................................................................75
3.1 Cavitation and Degassing Nuclei .............................................75
3.2 Mechanism of Ultrasonic Degassing .......................................81
3.3 Ultrasonic Degassing in a Stationary Volume .........................90
3.4 Ultrasonic Degassing in the Flow ...........................................98
References ........................................................................................106
Chapter 4 Ultrasonic Filtration .........................................................................109
4.1 Effect of Ultrasound on Surface Tension and Wetting ..........109
4.2 Sonocapillary Effect ..............................................................113
4.3 Basics of Filtration .................................................................115
4.4 Mechanism of Ultrasonic Melt Filtration ..............................120
4.5 Filtering through Multilayer Screen Filters: Usfirals
Process ...................................................................................122
References ........................................................................................128
vii
viii Contents
Chapter 5 Ultrasonic Grain Refinement ...........................................................129
5.1 Mechanisms of Ultrasonic Grain Refinement .......................129
5.2 Activation of Substrates .........................................................131
5.3 Deagglomeration and Dispersion of Particles .......................139
5.4 Refinement of Nucleating Intermetallics ...............................144
5.5 Dendrite Fragmentation .........................................................148
5.6 Nondendritic Solidification....................................................151
5.7 Ultrasonic Melt Processing in the Mold ................................162
5.8 Ultrasonic Melt Processing in the Melt Flow ........................166
References ........................................................................................168
Chapter 6 Refinement of Primary Particles ......................................................171
6.1 Formation of Primary Particles during Solidification ...........171
6.2 Effect of Ultrasound on Solidification of Intermetallic
Compounds ............................................................................172
6.3 Effect of Ultrasound on the Solidification of
Hypereutectic Al–Si Alloys ...................................................181
References ........................................................................................191
Chapter 7 Ultrasonic Processing during Direct-Chill Casting
of Light Alloys ..............................................................................193
7.1 Direct-Chill Casting of Aluminum Alloys ............................194
7.1.1 Ultrasonic Processing in the Sump of a Billet .........194
7.1.2 Ultrasonic Melt Processing in the Launder ..............205
7.2 Direct-Chill Casting of Magnesium Alloys ..........................207
7.3 Effect of Ultrasonic Degassing and Filtration on
Structure and Properties of Wrought Products .....................213
7.3.1 Ultrasonic Degassing................................................213
7.3.2 Ultrasonic Filtration .................................................215
7.4 Effect of Nondendritic Structure on Structure and
Properties of Wrought Products ............................................216
7.4.1 Aluminum Wrought Alloys ......................................216
7.4.2 Magnesium Wrought Alloys ....................................225
7.5 Effect of Nondendritic Grain Structure on
Homogenization .................................................................230
References ........................................................................................231
Chapter 8 Ultrasonic Melt Processing during Shape Casting of Light
Alloys ...........................................................................................235
8.1 Technological Approaches to Shape Casting with
Ultrasonic Processing ............................................................235