Near-Liquidus Rheomolding of Injectable Alloy
Disclosed is a process having an operation. The operation includes near-liquidus rheomolding of a molten light-metal alloy being injectable, under pressure, into a mold.
1 . A process, comprising:
an operation, including near-liquidus rheomolding of a molten light-metal alloy being injectable, under pressure, into a mold.
2 . The process of claim 1 , further comprising:
a first operation, including receiving a solidified light-metal alloy.
3 . The process of claim 2 , further comprising:
a second operation, including heating the solidified light-metal alloy associated with the first operation above a liquidus temperature of the solidified light-metal alloy, the solidified light-metal alloy becoming the molten light-metal alloy.
4 . The process of claim 3 , further comprising:
a third operation, including cooling the molten light-metal alloy associated with the second operation between the liquidus temperature and a solidus temperature of the molten light-metal alloy, so that the molten light-metal alloy includes a solids fraction content of less than 5%.
5 . The process of claim 4 , further comprising:
a fourth operation, including injecting, under pressure, the molten light-metal alloy resulting from the third operation into a mold cavity of the mold so that the molten light-metal alloy may become solidified in the mold.
6 . A process, comprising:
a first operation, including receiving a solidified light-metal alloy;
a second operation, including heating the solidified light-metal alloy associated with the first operation above a liquidus temperature of the solidified light-metal alloy, the solidified light-metal alloy becoming a molten light-metal alloy;
a third operation, including cooling the molten light-metal alloy associated with the second operation between the liquidus temperature and a solidus temperature of the molten light-metal alloy, so that the molten light-metal alloy includes a solids fraction content of less than 5%; and
a fourth operation, including injecting, under pressure, the molten light-metal alloy resulting from the third operation into a mold cavity of a mold so that the molten light-metal alloy may become solidified in the mold.
7 . The process of claim 1 , wherein the molten light-metal alloy includes an AZ91D alloy, and the liquidus temperature of the AZ91D alloy is nominally 595° C.
8 . A material input of the process of claim 1 .
9 . An article made by the process of claim 1 .
10 . A system operable according to the process of claim 1 .
11 . A computer program product for carrying a computer program embodied in a computer-readable medium being configured to instruct a controller to direct a system to perform, at least in part, the process of claim 1 .
12 . A controller including a computer program product for carrying a computer program embodied in a computer-readable medium adapted to perform, at least in part, the process of claim 1 .
13 . A system, comprising:
a receiver assembly configured to perform a first operation, including receiving a solidified light-metal alloy;
a heater assembly configured to perform: (i) a second operation, including heating the solidified light-metal alloy associated with the first operation above a liquidus temperature of the solidified light-metal alloy, the solidified light-metal alloy becoming a molten light-metal alloy, and (ii) a third operation, including cooling the molten light-metal alloy associated with the second operation between the liquidus temperature and a solidus temperature of the molten light-metal alloy, so that the molten light-metal alloy includes a solids fraction content of less than 5%; and
an injector assembly configured to perform a fourth operation, including injecting, under pressure, the molten light-metal alloy resulting from the third operation into a mold cavity of a mold so that the molten light-metal alloy may become solidified in the mold.
14 . The system of claim 13 , wherein:
the receiver assembly is coupled to the heater assembly ; and
the receiver assembly is coupled to the injector assembly.
15 . A system, comprising:
an extruder including:
(i) a receiver assembly, including:
a hopper;
a feed throat coupled to the hopper;
a barrel assembly connected with the feed throat, the hopper, the feed throat and the barrel assembly configured to perform a first operation, including receiving a solidified light-metal alloy;
(ii) a heater assembly coupled to the barrel assembly, the heater assembly configured to perform: (i) a second operation, including heating the solidified light-metal alloy associated with the first operation above a liquidus temperature of the solidified light-metal alloy, the solidified light-metal alloy becoming a molten light-metal alloy, and (ii) a third operation, including cooling the molten light-metal alloy associated with the second operation between the liquidus temperature and a solidus temperature of the molten light-metal alloy, so that the molten light-metal alloy includes a solids fraction content of less than 5%; and
(iii) an injector assembly, including:
a machine nozzle connected with an output of the barrel assembly, the machine nozzle configured to convey the molten light-metal alloy away from the barrel assembly toward a mold;
a screw, the barrel assembly configured to receive the screw; and
a motor coupled to the screw, the motor configured to drive the screw; and
a controller including:
a computer program product for carrying a computer program embodied in a computer-readable medium adapted to direct the controller to control the motor so that the motor may actuate the screw so as to perform a fourth operation, including injecting, under pressure, the molten light-metal alloy resulting from the third operation into a mold cavity of the mold so that the molten light-metal alloy may become solidified in the mold.
16 . The system of claim 15 , further comprising:
a stationary platen configured to support a stationary mold portion of the mold;
a movable platen configured to support a movable mold portion of the mold, the movable platen being movable relative to the stationary platen so as to close the stationary mold portion against the movable mold portion; and
a clamp assembly configured to apply a clamping force to the stationary platen and the movable platen so that the stationary mold portion remains closed against the movable mold portion as the mold receives the molten light-metal alloy.