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    • 专利摘要:
    electromagnetic formation of metallic glasses using a capacitive discharge and magnetic field. an apparatus and method for uniformly heating, theologically smoothing, and thermoplasticly forming metallic glasses rapidly into a final form using a rapid capacitor discharge forming tool (rcdf) in copulation with an electromagnetic force generated by the interaction of the applied current with a transverse magnetic field . The RFCF method utilizes the discharge of electrical energy stored in a capacitor to uniformly and rapidly heat a sample or charge of the metallic glass alloy at a predetermined process temperature between the amorphous metal glass transition temperature and the melting point of the glass. alloy equilibrium on a timescale of several milliseconds or less, whose potent interaction between the electric field and the magnetic field generates a force capable of forming the heated sample at a high quality amorphous volume through any number of techniques including, for example, injection molding, dynamic forging, seal forging, and blow molding in a time scale of less than one second.
    公开号:BR112012025734B1
    申请号:R112012025734
    申请日:2011-04-08
    公开日:2018-09-18
    发明作者:Kaltenboeck Georg；Samwer Konrad；D Demetriou Marios；N Robert Scott；L Johnson William
    申请人:California Inst Of Techn；
    IPC主号:
    专利说明:

    (54) Title: METHOD FOR HEATING AND FAST PLASTIC CONFORMATION OF AN AMORPHUS METAL USING ELECTRIC ENERGY DISCHARGE IN THE PRESENCE OF A MAGNETIC FIELD THAT GENERATES AN ELECTROMAGNETIC FORCE (51) Int.CI .: C22F 1/00; C22F 3/02; 1/21 C21D; B21D 26/14; C22C 45/00 (30) Unionist Priority: 08/04/2010 US 61 / 322,209 (73) Holder (s): CALIFORNIA INSTITUTE OF TECHNOLOGY (72) Inventor (s): WILLIAM L. JOHNSON; GEORG KALTENBOECK; MARIOS D. DEMETRIOU; KONRAD SAMWER; SCOTT N. ROBERT (85) National Phase Start Date: 08/10/2012
    1/25
    Invention Patent Report for METHOD FOR HEATING AND FAST PLASTIC CONFORMATION OF AN AMORPHUS METAL USING ELECTRICAL ENERGY DISCHARGE IN THE PRESENCE OF A MAGNETIC FIELD THAT GENERATES AN ELECTROMAGNETIC FORCE.
    Field of the Invention [001] This invention generally relates to a new method for forming metallic glass; and more particularly to a process for forming metallic glass using the rapid heating of the capacitor discharge and a magnetic field to apply an electromagnetic forming force.
    Background of the invention [002] Amorphous materials is a new class of engineering material, which has a unique combination of high strength, elasticity, corrosion resistance and processability of the molten state. Amorphous materials differ from conventional crystalline alloys in that their atomic structure lacks the typical ordered long-range patterns of the atomic structure of conventional crystalline alloys. Amorphous materials are generally processed and formed by cooling a molten alloy above the melting temperature of the crystalline phase (or the thermodynamic melting temperature) to below the transition temperature of the amorphous phase glass at sufficiently fast cooling rates, that the nucleation and growth of the alloy crystals are prevented. Thus, processing methods for amorphous alloys have always been concerned with quantifying the sufficiently rapid cooling rate, which is also referred to as the critical cooling rate, to ensure the formation of the amorphous phase.
    [003] Critical cooling rates for almost amorphous materials were extremely high, on the order of 10 6 ° C / sec. Like this,
    Petition 870180021286, of 03/16/2018, p. 7/41
    2/25 conventional casting processes were not suitable for such high cooling rates, and special casting processes such as melting and planar flow casting were developed. Due to the crystallization kinetics of the substantially fast anticipated alloys, the extremely short time (on the order of 10 -3 seconds or less) for the extraction of heat from the molten alloy was necessary to bypass the crystallization, and thus anticipated amorphous alloys were also present. limited in size to at least one dimension. For example, only metal sheets and very thin strips (around 25 microns in thickness) have been successfully produced using these conventional techniques. Because of the critical cooling rate requirements for these amorphous alloys, the size of the parts made of amorphous alloys was severely limited, the early use of amorphous alloys as bulky parts and objects was limited.
    [004] Over the years it has been determined that the critical cooling rate depends heavily on the chemical composition of amorphous alloys. Certainly, a great deal of research was focused on the development of new alloy compositions with much lower critical cooling rates. Examples of these alloys are given in United States Patent Nos. 5,288,344; 5,368,659; 5,618,359; and 5,735,975, each of which is incorporated herein by reference. These amorphous alloy systems, also called bulky metallic glasses or BMGs, are characterized by critical cooling rates as low as some ° C / second, which allows the processing and formation of objects in the large amorphous phase much higher than those previously obtained .
    [005] With the availability of low critical cooling rate BMGs, it became possible to apply conventional casting processes to form bulky parts having an amorphous phase. For many years, many companies, including LiquidMetal TechnoPetição 870180021286, from 03/16/2018, p. 8/41
    3/25 logies, Inc. made an effort to develop commercial manufacturing technologies for the production of metallic parts in the final form of BMGs. For example, manufacturing methods such as permanent mold metal die casting and heated die casting are currently being used to manufacture commercial hardware components and components such as electronic housings for standard consumer electronic devices (eg, cell phones and devices cordless devices), hinges, fasteners, medical instruments and other value-added products. However, although the bulky amorphous solidification alloys provide some solution to the fundamental deficiencies of solidification casting, and particularly to the die casting and mold casting processes, as discussed above, there are still issues that need to be addressed. First and foremost, there is a need to make these bulky objects from a broader range of alloy compositions. For example, BMGs currently available with large critical casting dimensions capable of making amorphous objects in high volume are limited to a few groups of alloy compositions in a very narrow selection of metals, including Zr-based alloys with base-based alloy additions. in Ti, Ni, Cu, Al and Be and Pd with additions of Ni, Cu, and P, which are not necessarily optimized from an engineering or cost perspective.
    [006] In addition, current processing technology requires a lot of expensive machinery to ensure the proper processing conditions are created. For example, most plastic forming processes require a high vacuum or controlled inert gas environment, material induction melting in a crucible, metal leakage in an injection sleeve, and pneumatic injection through an injection sleeve. acquisition and cavities of a more elaborate set of molds. These modified die casting machines were modified 870180021286, from 03/16/2018, p. 9/41
    4/25 registrations can cost several hundred thousand dollars per machine. In addition, because the heating of a BMG has so far been carried out through these traditional slow thermal processes, the prior processing and formation of bulky solidification amorphous alloys has always focused on cooling the molten alloy above the thermodynamic melting temperature below the glass transition temperature. This cooling was carried out using a monotonous single-step cooling operation or a multi-stage process. For example, metal molds (made of copper, steel, tungsten, molybdenum, composites of these, or other high conductivity materials) at room temperatures are used to facilitate and accelerate the extraction of heat from the molten alloy. Because the critical casting dimension is correlated with the critical cooling rate, these conventional processes are not suitable for forming large pieces and bulky objects from a wider range of bulky solidifying amorphous alloys. In addition, it is generally necessary to inject the molten alloy into the matrices at high speed and under high pressure, to ensure that sufficient material from the alloy is introduced into the matrix before the alloy solidifies, particularly in the manufacture of complex and high precision parts. Because the metal is inserted into the matrix under high pressure and at high speeds, as in the high pressure die casting operation, the flow of the molten metal becomes prone to Rayleigh-Taylor instability. This flow instability is characterized by a high Weber number, and is associated with the breakage of the flow causing the formation of projected layers and cells, which appear as structural and cosmetic microdefects in the casting parts. In addition, there is a tendency to form a contracted cavity or porosity along the center line of the injected casting mold when the non-vitrified liquid is trapped within a solid vitrified metal shield.
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    5/25 [007] Attempts to remedy the problems associated with the rapid cooling of the material above the equilibrium melting point to below the glass transition were mainly focused on the use of kinetic stability and viscous flow characteristics of the supercooled liquid. Methods have been proposed involving heating glassy raw materials above the glass transition where the glass is in a viscous supercooled liquid, applying pressure to form the supercooled liquid, and subsequently cooling below the glass transition before crystallization. These attractive methods are essentially very similar to those used to process plastics. In contrast to plastics, however, which remain stable against crystallization above the smoothing transition for extremely long periods of time, supercooled metallic liquids crystallize more quickly once relaxed in the glass transition. Consequently, the temperature range in which metallic glasses are stable against crystallization when heated at conventional heating rates (20 ° C / min) is lower (50 100 ° C above the glass transition), and the viscosity of the liquid within this range is higher (10 9 - 10 7 Pa-s). Due to these high viscosities, the pressures necessary to form these liquids in desirable forms are enormous, and many alloys of metallic glass could exceed the pressures obtained by the conventional high strength tool (<1 GPa). Metal glass alloys have recently been developed and are stable against crystallization when heated at conventional heating rates to considerably high temperatures (165 ° C above the glass transition). Examples of these alloys are given in US Patent Application 20080135138 and articles by G. Duan et al. (Advanced Materials, 19 (2007) 4272) and A. Wiest (Act Materialia, 56 (2008) 2525-2630), each of which is incorporated herein by reference. Due to its high stability against
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    6/25 crystallization, process viscosities as low as 10 5 Pa-s become accessible, which suggests that these alloys are more suitable for processing in the super-cooled state than traditional metal glasses. These viscosities, however, are still substantially higher than the viscosities of plastics processing, which typically range between 10 and 1000 Pa-s. In order to obtain low viscosities, the metallic glass alloy must exhibit an even higher stability against crystallization when heated by conventional heating, or be heated to a high rate of unconventional heating that would extend the temperature range of the stability and reduce the viscosity process to values typical of those used in thermoplastic processing.
    [008] Some attempts have been made to create a method of instantaneous heating of a BMG to a temperature sufficient for formation, thus avoiding many of the problems discussed above and simultaneously expanding the types of amorphous materials that can be formed. For example, U.S. Patent 4,115,682 and 5,005,456 and articles for AR Yavari (Materials Research Society Symposium Proceedings, 644 (2001) L12-20-1, Materials Science & Engineering A, 375-377 (2004) 227-234; and Applied Physics Letters, 81 (9) (2002) 1606-1608), the disclosures of each of these are incorporated by reference, all with the advantage of the unique conductive properties of amorphous materials to instantly heat the materials to a plastic forming temperature using Joule heating. However, until now these techniques have focused on the localized heating of BMG samples to allow only localized formation, such as the joining (that is, spot welding) of such parts, or the formation of surface functions. None of these prior art methods teach how to uniformly heat the entire volume of the BMG sample to perfection 870180021286, from 03/16/2018, pg. 12/41
    7/25 to avoid undertaking global training. In addition, all of these prior art methods anticipate temperature gradients during heating, and discuss how these gradients could affect local formation. For example, Yavari et al (Materials Research Society Symposium Proceedings, 644 (2001) L12-20-1) writes: The external surfaces of the BMG sample being formed, whether in contact with the electrodes or with the (inert) gas in the environment plastic conformation camera, will be slightly cooler than the internal part as the heat generated by the current dissipates outside the sample by conduction, convex or radiation. On the other hand, the external surfaces of samples heated by conduction, convex or radiation are slightly warmer than the internal ones. This is an important advantage for the present method as crystallization and / or oxidation of metallic glasses usually being first on the external surfaces and interfaces and if they are slightly below the volume temperature, such undesirable crystal formation of the surface can be avoided more easily. .
    [009] Another disadvantage of the limited stability of BMGs against crystallization above the glass transition is the inability to measure thermodynamic properties and transport properties, such as heat capacity and viscosity, over the entire temperature range of the supercooled metastable liquid . Typical measuring instruments such as Differential Scanning Heat Meters, Thermomechanical Analyzers, and Coquette Viscometers depend on conventional heating instrumentation, such as electric and induction heaters, and are then able to obtain the sample heating rates that are considered conventional ( typically <100 ° C / min). As discussed above, supercooled metal liquids can be stable against crystallization over a limited temperature range when heated to a heating rate
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    Conventional 8/25, and thus the transportable and measurable thermodynamic properties are limited within the accessible temperature range. Consequently, polymer and different organic liquids that are very stable against crystallization and their thermodynamic and transport properties are measurable across the metastability range, the properties of supercooled metal liquids are only measurable within the narrow temperature ranges above the transition from glass and below the melting point.
    [0010] Recently, a method has been developed and overcomes many limitations of these conventional methods by uniform heating, theological smoothing, and thermoplastic formation of metal glasses quickly in a final shape using a net shape tool (RCDF). (See, for example, North American Patent Publication No. US-2009-023601 7-A1, the disclosure that is incorporated herein by reference). The RCDF method uses the discharge of electrical energy stored in a capacitor to evenly and quickly heat a sample or charge from the alloy of the metallic glass to a predetermined process temperature between the glass transition temperature of the amorphous material and the melting point of alloy balance on a time scale of several milliseconds or less. However, in this method the application of force to form the heated sample in high-quality bulky amorphous articles is done through conventional techniques, which are not optimal.
    [0011] Certainly, a need exists to find a new approach to form a heated BMG sample that explains the electric field generated in the instantaneous RCDF heating method.
    Summary of the Invention [0012] A method for forming metallic glass, sheets, tubes, or rods is disclosed that utilizes a force from electromagnetic formation
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    9/25 to form a charge of the metallic glass in the form of an essentially uniform blade, tube, or cross-section rod.
    [0013] In one embodiment, the invention is directed to a method for heating and fast plastic forming of an amorphous material using a quick discharge of the capacitor and electromagnetic force, and includes:
    • provide at least a sample of amorphous metal having a substantially uniform cross-section;
    • discharge a quantum of electrical energy uniformly through each of the samples along an axis of the electric field to evenly heat the entire sample to a processing temperature so that the viscosity of the amorphous material is between approximately 1 Pa-s at approximately 10 5 Pa-s;
    • apply a static magnetic field across the axis of the electric field to generate an electromagnetic deformation force to form the heated sample in an amorphous article; and • cool the article to a temperature below the glass transition temperature of the amorphous material.
    [0014] In another embodiment, the invention is directed to an apparatus for magnetic formation to quickly heat and shape an amorphous metal, including:
    • a sample of amorphous metal having a substantially uniform cross-section;
    • a source of electrical energy;
    • at least two electrodes that interconnect fixed to the sample so that substantially uniform connections are formed between said electrodes and said sample, in which the source of electrical energy is capable of producing a quantum of electrical energy along an axis of the enough electric field to evenly
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    10/25 heating all said sample to a processing temperature so that the viscosity of the amorphous material is between approximately 1 Pa-s to approximately 10 5 Pa-s;
    • a source of the static magnetic field arranged so that a static magnetic field is produced across the axis of the electric field; and • where the static magnetic field in association with the quantum of electrical energy is capable of generating an electromagnetic deformation force sufficient to form said heated sample in an article.
    [0015] In yet another modality, the quantum of electrical energy is discharged through the electrodes to generate an electric field along the longitudinal length of the sample.
    [0016] In yet another modality, the quantum of electrical energy is at least approximately 100 J and a discharge time constant between approximately 10 ps and 10 ms.
    [0017] In yet another modality, the heating and plastic shaping of the sample are completed in a period between approximately 100 ps to 1 s.
    [0018] In yet another modality, the intensity of the quantum of electrical energy is varied during at least one of the stages of heating and plastic shaping. In such an embodiment, the variation includes generating a quick pre-pulse in the sample before discharging more energy at a slower rate, the energy of said pre-pulse being sufficient to uniformly increase the temperature of the sample above the glass transition of the amorphous material , while the energy discharged at a slower rate is sufficient to interact with the magnetic field to generate an electromagnetic force to sufficiently form the heated sample.
    [0019] In yet another modality, the sample has a sePetição form 870180021286, dated 03/16/2018, p. 16/41
    11/25 taught by the group consisting of rods, blades, cylinders, and cubes.
    [0020] In yet another modality, the magnetic field is arranged in relation to the axis of the electric field so that the electromagnetic deformation force is formed normal to the axis of the electric field.
    [0021] In yet another modality, the source of electrical energy is a capacitor.
    [0022] In yet another modality, the magnetic field is formed by at least one magnetic source selected from the group consisting of permanent magnets and electromagnets, such as Helmholtz coils or a Helmholtz coil combined with a light magnetic core. high permeability. In this modality, permanent magnets are selected from the group consisting of iron-neodymium-boron magnets and samarium cobalt magnets.
    [0023] In yet another modality, the magnetic field is formed from the combined influence of a plurality of magnetic sources. In this modality, the plurality of magnetic sources is arranged at different angles with respect to the axis of the electric field. In another embodiment, a plastic forming tool is arranged in the vicinity of said sample, the plastic forming tool having a three-dimensional mold cavity.
    [0024] In yet another modality, the apparatus and method includes a plastic forming tool in the vicinity of the sample so that the deformation force stimulates the amorphous material in contact with a plastic forming tool selected from the group consisting of molds, dies , extrusion dies, injection molds, seals and rollers. In this mode, the plastic forming tool is heated to a temperature preferably around the transition temperature of the glass of the amorphous material. In another fashionPetition 870180021286, of 03/16/2018, p. 17/41
    12/25 lity, the plastic forming tool is at least partially formed of a magnetic material.
    [0025] In yet another modality, the forming tool is a pair of parallel rollers, in which the magnetic field is applied normal to the sample and parallel to a plane defined by the roller axes so that said sample is stimulated between the said rollers to form an amorphous blade article.
    [0026] In yet another modality, the apparatus includes confining the sample along at least two axes within a channel formed by a non-conductive containment member and discharging the quantum of energy across the width of the sample so that a deformation force be applied along the length of the sample to create a pressure gradient in the sample so that the heated sample is stimulated along the channel and injected into a forming tool. In such an embodiment, the forming tool is a matrix or a mold.
    [0027] In yet another modality, the sample contact surfaces between the electrodes and the sample are flat and parallel.
    Brief Description of the Drawings [0028] The description will be understood more fully with reference to the following figures, which are presented as exemplary modalities of the invention and should not be constructed as a complete recitation of the scope of the invention, in which:
    [0029] Figure 1 provides a schematic diagram of the layout and geometry of a modality of the electromagnetic formation method of the current invention;
    [0030] Figures 2A to 2D provide a demonstration of the electromagnetic molding according to the current invention, where (A) provides an image of the initialization before discharge showing 1-inch wide tape, copper electrodes and permanent magnet, (B) provides
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    13/25 an image of the apparatus that follows the discharge, (C) provides an image of a blade formed on a Macor mold according to an exemplary embodiment of the current invention, and (D) provides a series of other images showing the electromagnetic molding process according to the current invention;
    [0031] Figure 3 provides a schematic of an apparatus for the magnetically driven bearing of a heated metallic glass plate to form a blade according to an embodiment of the invention;
    [0032] Figure 4 provides a schematic of an electromagnetic force generated by a permanent magnetic field to perform the injection molding of a charge confined in a mold tool according to an embodiment of the invention;
    [0033] Figure 5 provides a schematic of a device geometry suitable for discharging the electromagnetic heating forces to connect the adjacent blades according to an embodiment of the invention; and [0034] Figure 6 provides a schematic data graph of an adapted current profile comprising two successive pulses of different intensity and duration according to an embodiment of the invention.
    Detailed Description of the Invention [0035] The current invention is directed to a method of uniform heating, theological smoothing, and thermoplastic formation of metal glasses quickly (typically with processing times of less than 1 second) in an article in final form using a force of electromagnetic formation in conjunction with Joule heating.
    Capacitor Fast Discharge Formation (RCDF) [0036] The current invention method uses energy discharge
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    14/25 electric (typically 100 J to 100 KJ) stored in a capacitor to evenly and quickly heat a sample or alloy charge from the metallic glass to a predetermined process temperature approximately halfway between the glass transition temperature of the amorphous material and the equilibrium melting point of the alloy on a time scale of several milliseconds or less in combination with a force of the magnetic formation, and is referred to below as the magnetically permitted capacitor fast discharge formation (MERCDF). A conventional RCDF process is described in more detail in U.S. Patent Publication US2009-0236017-A1, the disclosure of which is incorporated herein by reference.
    [0037] The conventional RCDF process proceeds from the observation that metallic glass, due to its virtue of being a frozen liquid, has a relatively high electrical resistance, which can result in sufficient and efficient high dissipation, uniform heating of the material in the shape rate. that the sample is evenly heated over the very short period of time with the correct application of an electrical discharge. By rapidly and uniformly heating a BMG, the RCDF method extends the stability, the supercooled liquid against crystallization to temperatures substantially higher than the glass transition temperature, thus putting the entire sample volume into a state associated with a processing viscosity that is great for forming. The RCDF process also provides access to the entire range of viscosities offered by the metastable supercooled liquid, as this range is no longer limited by the formation of the stable crystalline phase.
    [0038] In summary, the RCDF process allows the improvement of the quality of the formed parts, an increase in the production of usable parts, a reduction in the material and processing courses,
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    15/25 an extension of the range of usable MMG materials, improved energy efficiency, and lower capital cost of manufacturing machines. In addition, due to the instantaneous and uniform heating that can be obtained in the RCDF method, the thermodynamic and transport properties throughout the range of the liquid metastability become accessible for measurement.
    Formation of the Magnetic Field [0039] The electromagnetic formation of the current invention must be contrasted with the conventional electromagnetic formation (EM formation or Magne formation). Conventional EM forming is a type of cold, high-speed forming process for electrically conductive metals, most commonly copper and aluminum. In this process the workpiece is reformed by high intensity pulsed magnetic fields that induce a current in the workpiece and a corresponding repulsive magnetic field, quickly repelling parts of the workpiece. During operation, a rapidly changing magnetic field induces a circulating electrical current within a nearby conductor through electromagnetic induction. The induced current creates a corresponding magnetic field around the conductor. Because of Lenz's Law, the magnetic fields created inside the conductor and the working coil strongly repel each other. The high current of the work coil (typically tens or hundreds of thousands of amps) creates an ultra-strong magnetic force that exceeds the production force of the ambient temperature of the metal workpiece, causing permanent deformation. However, this process requires the metal to be formed in a cold state.
    [0040] As discussed, the current invention provides a method for forming metallic glass, blades, tubes, or rods, which uses a charge of the metallic glass in the form of an essentially uniform blade, tube, or cross-section rod. During the process, a
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    16/25 large current pulse generated by the discharge of a capacitor bank across the length of the sample is used to quickly and evenly heat the sample to a target temperature in the super-cooled liquid region. After heating, the heated sample is subjected to an electromagnetic force generated by the interaction of the applied current with a magnetic field normally oriented in the direction of the current flow.
    [0041] Figure 1, below, shows a schematic illustration of an exemplary geometry used in the implementation of the invention. In the example geometry used for illustration, the sample (10), which is arranged in a position adjacent to a plastic forming element (12), such as a mold, injection molding port, cylinder blade, etc., is heated by applying an electric current applied (I) by the sample. The heated sample is then subjected to an electromagnetic force (F) formed by the applied current (I) of the inductive heating and the transverse magnetic field (B), which in this example is normal to the current. The sample is shaped by the resulting electromagnetic force, as the heated sample is a viscous liquid, which deforms under the influence of the electromagnetic force to replicate the shape defined by the plastic forming element (in the example in figure 1, a mold).
    [0042] It is observed that most metallic glasses are non-magnetic, especially above their transition from glass, and so it is not obvious that an electromagnetic formation process would operate them. However, the electromagnetic formation operates in these amorphous systems, since the metallic glass is simultaneously being heated by the generation of an electric field while present in a transverse magnetic field.
    [0043] Below is a list of the basic elements that allow the combined use of capacitive discharges and magnetic fields for
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    17/25 carry out the processing and formation in the final form of the metallic glass materials. To a person skilled in the art, it should be apparent that many variations are possible within the basic invention, however, for the purposes of disclosure, the invention can be defined and characterized by the following basic elements:
    [1] The sample [0044] A charge of metallic glass having an essentially uniform cross-section. Although a uniform cross-section is necessary, it should be understood that any shape with uniform cross-section can be used, for example, rods, blades, cylinders, hubs, etc. Likewise, any metallic glass having an accessible amorphous phase can be used, such as, for example, metallic glass disclosed in United States Patent Nos. 5,288,344; 5,368,659; 5,618,359; and 5,735,975, the disclosures of each are incorporated herein by reference.
    [2] The electrical circuit [0045] An electrical capacitor that is used to store and discharge electrical energy by uniform ohmic dissipation with an electrical current along the length of the sample thus evenly heating the sample and a liquid processing temperature above glass transition temperature of metallic glass in accordance with United States Patent Publication No. US2009-0236017-A1, the disclosure that is incorporated herein by reference.
    [3] The processing temperature [0046] The processing temperature chosen to be in a range and that the viscosity of the liquid that forms the glass is between approximately 1 Pas-s to approximately 10 5 Pas-s. It should be understood that the methods of determining the necessary temperature place any metallic glass within this range of vision 870180021286, of 03/16/2018, pg. 23/41
    18/25 cosiness are well known to those skilled in the art.
    [4] The nature of the magnetic field [0047] A static magnetic field applied in the region around the sample that reacts with the time and space dependent current flowing in the sample to produce electromagnetic forces that act on the sample to form and form the sample liquid in a desired shape. Plastic forming and forming can be carried out with or without the use of an auxiliary plastic forming tool, such as a mold, die, blade cylinder, extruder, etc. (Several examples of different plastic forming tools incorporated with the plastic field forming process of the current invention are shown in examples 1 to 6, below.) [5] The geometry of the magnetic field [0048] Although the magnetic field is static , can generally vary in space so that it controls the distribution of the electromagnetic plastic forming forces on the sample to produce the optimal formation of a final shape. In particular, although in the basic example provided in figure 1, above, the geometry of the magnetic field with respect to the applied current is chosen so that the electromagnetic force applied to the sample is directed normal to the sample and against a matrix tool or a tool mold should be understood that the force applied to the sample is proportional to the angle of the current and the magnetic field according to the equation of Lorentz force [F => xBsin <& f or O pushes against the normal sample to sample. Certainly, the magnetic field and the electric current can be positioned with respect to each other in any suitable geometry to apply the necessary plastic forming force to the sample. For example, the field can be produced by a single or several permanent magnets arranged in a configuration for
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    19/25 produce a desired distribution of forces on the sample. The static magnetic field can also be created in part by electromagnets. Electromagnets can be used with one or more permanent magnets. The permanent magnets can be of the type Ferro-Neomidium Boron, type Samarium-Cobalt, or another common type of permanent magnet. Alternatively, the mold itself could also be manufactured from a magnetic material.
    [6] Satiation [0049] Following the plastic conformation, the final part is cooled below the glass transition temperature of the metallic glass in a sufficiently short period of time to avoid substantial crystallization of the part. The final component produced then remains in a substantially glassy state. For definition purposes, the final part must comprise at least 50% metallic glass and less than 50% any crystallized material. Cooling can be carried out by any reasonable means, including, for example, thermal conduction to the mold tool, or by conduction, convexation, or radiation at room temperature around the final meshed component.
    [0050] Although a basic modality of the MERCDF method of the current invention is described above, as are the basic elements needed to use a magnetic field to create the electromagnetic forming forces in a workpiece of metallic glass that carries the current, it must be understood that the method can be extended to various geometries and other forming methods. For example, several permanent magnets with high field strength Ferro-Neodymium-Boron permanent magnets can be used to produce spatially non-uniform permanent fields that interact with the sample stream to produce a desired distribution to form forces on the workpiece. This force distribution
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    20/25 acting on the workpiece can be adapted to optimize the network's plastic forming capacity of the invention. In addition, since the magnetic forces are scaled with the current while the heat dissipation in the load is scaled quadratically with the current, one can also use the discharge from the various capacitors to separately control the heating and plastic conformation of the sample. These variations and others will be described more fully in the exemplary modalities presented below.
    Exemplary modalities [0051] As examples of the invention that incorporate the basic elements above, the exemplary coatings following the final form formation of the various initial forms to the final useful parts are provided. The examples given here are intended to illustrate several useful variants of the basic invention. All of these variants are based on the basic elements of the invention as described at the beginning of this section. These variants are to be considered as alternative embodiments of the invention as disclosed herein. The invention has many other possible variants that can be implemented by the skilled person using modified geometries as needed to produce an appropriate arrangement of electromagnetic forces in a workpiece heated by capacitive discharge.
    Example 1: Molding [0052] As a demonstration of the method in a simple molding coating, a thin sheet of metallic glass (Metglas MBF 50 - Ni-based brazing alloy produced by the planar flow casting is used. The blade is in form of a band of width 1-2, thickness of approximately 30-40 pm. Such bands are commercially available in long lengths from Metglas Division of Hitachi Metals. A 0.262 capacitor band ContradPetition 870180021286, from 16/03/2018, page 26/41
    21/25 by a silicone rectifier was used. A simple tool from the demonstration die was made of machinable ceramic, Macor. For demonstration, a Macor matrix of circular symmetry with concentric grooves manufactured on the surface was chosen as shown in figures 2A to D.
    [0053] A reasonably homogeneous magnetic field of ~ 1 kG was applied in the region around the mold and was provided by a permanent magnet as seen in figures 2A and 2B. The capacitor was charged at voltages in the range of 20-40 volts and discharged through copper wires and a copper fixing strip in the range. Figure 2A shows the original strip in the magnetic field before discharge. Figure 2B shows the strip as heated in the magnetic field by the capacitive discharge at a process temperature of -700C. Figure 2C shows the band formed after a total timeout of several seconds.
    [0054] A high speed video at 1000 structures / s shows that the sample is heated at the process temperature in several milliseconds, formed by the dynamic deformation in the mold within approximately 10 milliseconds after heating, and cooled to room temperature after time 1-2 out of total. The result, which is shown in a series of stills in figure 2D, demonstrates a proof of concept of the use of an electromagnetic force generated by the interaction of the sample current with a permanent magnetic field to compressively falsify a blade in a formed part.
    Example 2: Blade formation [0055] Figure 3 shows an exemplary configuration for a blade forming method from a plate using twin rollers. As shown, in this modality an electromagnetic force (F) is exerted on a square or rectangular bar (14) of glass
    Petition 870180021286, of 03/16/2018, p. 27/41
    22/25 metal located above the gap between the two rotating rollers (16). The electrical discharge (I) is transferred to the sample by the electrodes (not shown), which touch the ends of the bar (14). The current is induced along the length of the bar. A static magnetic field (B) is applied normal to the bar (14) and parallel to the plane defined by the two axes (18) of the twin rollers (16).
    [0056] The electromagnetic force drives the heated bar in the gap between the rollers to produce a rolled blade. The bar may be contained in a vertical channel (not shown) made of electrically non-conductive material in order to effectively and efficiently confine the material through the rollers.
    Example 3: Injection molding and extrusion of a component formed by mesh [0057] In another embodiment, the basic method can be used mold by injecting a square rod into a mold cavity in the final form. As shown in figure 4, in this modality an electromagnetic force (F) can be used to create a pressure gradient along the length of a sample of the metallic glass (20) during the discharge of heat from the rod by a current (I) by its width provided by the two bar-shaped electrodes (22). To prevent leakage, the load is confined by the non-conductive retaining walls (24). A mold tool with suitable coupling and mold cavity can be provided (not shown) which would then be filled with the injected liquid as it is heated to an appropriate process temperature (as described above).
    [0058] Alternatively, the same configuration can be used for an extrusion method of a component formed by a uniform cross-section network using an extrusion die. In this mode, the device is used to force a heated load of metallic glass through an extrusion die. In this case,
    Petition 870180021286, of 03/16/2018, p. 28/41
    23/25 the matrix would be located at the mold location in figure 4.
    Example 4: Multiple magnet formation [0059] In another embodiment, several magnets can be used to form a sheet in the form of a coating formed as a box in the form of a rectangular solid having a width and length greater than depth. As described above, it should be understood that a suitable configuration of several permanent magnets can be used to generate a distribution of forces on a workpiece, which can be adapted to form the workpiece in a three-dimensional mold cavity as a form of formed box, ring, spherical, or other desired shape.
    Example 5: Joining and connecting the components [0060] Two components (blades, bars, plates) can be heated by a capacitive discharge, simultaneously using the method of the current invention. If the direction of current flow in the two components is reversed, then the electromagnetic force can be used to drive the two components in contact. An example of this geometry is illustrated in figure 5. As shown, when the two bands (26) are heated by capacitive discharges (I) that have current flow opposite to an appropriate process temperature, an electromagnetic force (F) is uniformly exerted on the two surfaces, the two parts can be driven together and joined or connected.
    [0061] After joining, the pieces can be erased below the glass transition temperature using any suitable method, such as by conduction or convection to a suitable fluid, or through the surrounding radiation. For example, in one embodiment, the external surfaces of the parts could be exposed to a flow or reservoir of a gas or liquid, such as helium gas or a suitable oil bath.
    Petition 870180021286, of 03/16/2018, p. 29/41
    24/25
    Example 7: Plastic conformation of the current profile (“Current Profile
    Shaping ”) [0062] Because heating and training are essentially coupled in the present method, the current profile can be adapted so that the stages of heating and training are effectively decoupled. In one embodiment, for example, it is preferable to first apply a pulse of the high intensity short-term current first, followed by a second low-intensity long-term pulse. Since the heating rate is quadratically related to the current (~ l 2 ) while the force is linearly related to the current (~ l), the vast majority of heating will occur during the first pulse of high intensity short-term current, while the large Most of the formation will occur during the second low intensity long-term current pulse. Specifically, the first pulse will be used to quickly and evenly increase the sample temperature above the glass transition temperature at which point the sample viscosity starts to drop. Although the high current of the first pulse induces a high force, this force will not produce substantial formation, as the sample viscosity will be reasonably high for most of the duration of the first pulse. The second pulse with much lower intensity, but with much longer duration, will only result in another mild warming compared to the first pulse, as the warming is proportional to ~ l 2 . As the force is proportional to -I, however, the second pulse will induce a force not much less than that of the first pulse, applied over a much longer period of time during which the sample viscosity is much lower, thus contributing much more for training. This modality is demonstrated graphically in figure 6. [0063] In the modality described above, the magnetic field could be induced by electronically activating an electromagnet, as, for example,
    Petition 870180021286, of 03/16/2018, p. 30/41
    25/25 example, a Helmholtz coil, in sync with the quantum discharge of additional energy. Thus, heating and formation are more effectively decoupled, as no force will be induced during the first pulse of the current so that it is used only for heating.
    Equivalent theory [0064] Those skilled in the art will note that the examples and descriptions referred to of the various preferred embodiments of the present invention are merely illustrative of the invention as a whole, and that variations in the steps and the various components of the present invention can be made within of the spirit and scope of the invention. For example, it will be clear to a person skilled in the art that additional processing steps or alternative configurations would not affect the improved properties of the method / apparatus of the current invention or present the method / apparatus unsuitable for its purpose. Certainly, the present invention is not limited to the specific modalities described here, but it is still defined by the scope of the appended claims.
    Petition 870180021286, of 03/16/2018, p. 31/41
    1/4
    权利要求:
    Claims (21)
    [1]
    1. Method for heating and fast plastic forming of an amorphous metal using electrical energy discharge in the presence of a magnetic field that generates an electromagnetic force, the method characterized by the fact that it comprises the steps of:
    providing at least one sample of amorphous metal, said sample having a substantially uniform cross-section;
    discharge of a quantum of electrical energy uniformly through at least each of said samples along an axis of the electric field to evenly heat the entire said sample at a processing temperature so that the viscosity of the amorphous metal is between approximately 1 Pa-s at approximately 10 5 Pa-s;
    apply a static magnetic field across the axis of the electric field to generate an electromagnetic deformation force for plastic conformation of the heated sample; and cooling said article to a temperature below the transition temperature of the amorphous metal glass to produce an amorphous article.
    [2]
    2. Method, according to claim 1, characterized by the fact that the discharge step of said quantum of electrical energy occurs through at least two electrodes connected to the opposite ends of at least each of said samples and generates an electric field along the longitudinal length of said sample.
    [3]
    3. Method, according to claim 1, characterized by the fact that the quantum of electrical energy is carried through the discharge of a capacitor.
    [4]
    4. Method, according to claim 1, characterized by the fact that the quantum of electrical energy is at least approximately 870180021286, of 03/16/2018, p. 32/41
    2/4 approximately 100 Joules and a discharge time constant between approximately 10 ps and 10 ms.
    [5]
    5. Method, according to claim 1, characterized by the fact that the heating and plastic shaping of the sample is complete in a time between approximately 100 ps to 1 s.
    [6]
    6. Method, according to claim 1, characterized by the fact that it still comprises the variation of the quantum intensity of electrical energy during at least one between the heating or plastic shaping steps.
    [7]
    7. Method, according to claim 6, characterized by the fact that the step of variation includes generating a pre-pulse in the sample before the discharge of a quantum of additional energy at a first rate;
    the energy of said pre-pulse being sufficient to raise the temperature of the sample at the interface above the transition of the amorphous metal glass; and the quantum of additional energy being discharged at a slower rate than the rate of said pre-pulse with sufficient energy to interact with the magnetic field to generate sufficient electromagnetic force for plastic conformation of the heated sample.
    [8]
    8. Method, according to claim 7, characterized by the fact that the magnetic field is induced by the activation of an electromagnet in sync with the discharge of the additional energy quantum.
    [9]
    9. Method, according to claim 1, characterized by the fact that the sample has a shape selected from the group consisting of rods, blades, cylinders, and cubes.
    [10]
    10. Method, according to claim 1, characterized by the fact that the magnetic field is arranged in relation to the axis of the electric field so that the electromagnetic deformation forcePetition 870180021286, of 03/16/2018, p. 33/41
    3/4 ca is formed normal to the axis of the electric field.
    [11]
    11. Method, according to claim 1, characterized by the fact that the magnetic field is formed by at least one magnetic source selected from the group consisting of permanent magnets and electromagnets.
    [12]
    12. Method according to claim 11, characterized by the fact that permanent magnets are selected from the group consisting of boron-iron-neodymium magnets and samarium cobalt magnets.
    [13]
    13. Method according to claim 1, characterized by the fact that the magnetic field is formed from the combined influence of a plurality of magnetic sources.
    [14]
    14. Method, according to claim 13, characterized by the fact that the plurality of magnetic sources is arranged at different angles with respect to the axis of the electric field.
    [15]
    15. Method, according to claim 13, characterized by the fact that it still comprises providing a plastic forming tool in the vicinity of said sample, the plastic forming tool having a three-dimensional mold cavity.
    [16]
    16. Method, according to claim 1, characterized by the fact that it also comprises providing a plastic forming tool in the vicinity of said sample so that the deformation force stimulates the amorphous metal heated in contact with a selected plastic forming tool of the group consisting of molds, dies, extrusion dies, injection molds, seals and rolls.
    [17]
    17. Method according to claim 16, characterized by the fact that the plastic forming tool is heated to a temperature at or below the transition temperature of the amorphous metal glass.
    Petition 870180021286, of 03/16/2018, p. 34/41
    4/4
    [18]
    18. Method according to claim 16, characterized by the fact that the plastic forming tool is at least partially formed of a magnetic material.
    [19]
    19. Method, according to claim 16, characterized by the fact that the plastic forming tool is a pair of parallel rollers, and in which the magnetic field is applied normal to the sample and parallel to a plane defined by the axes of the rollers. so that said sample is stimulated between said rolls for plastic shaping of an amorphous blade article.
    [20]
    20. Method, according to claim 16, characterized by the fact that it still comprises providing an elongated sample;
    confine the sample along at least two axes within a channel formed by a non-conductive retaining member;
    discharge of the quantum of energy across the width of the samples; and applying a deformation force along the length of the sample to create a pressure gradient in the sample so that the heated sample is stimulated along the channel in a plastic forming tool.
    [21]
    21. Method according to claim 20, characterized by the fact that the forming tool is a matrix or a mold.
    Petition 870180021286, of 03/16/2018, p. 35/41
    1/8
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    JP2013530045A|2013-07-25|
    AU2011237361B2|2015-01-22|
    EP2556178A4|2017-11-29|
    US20130319062A1|2013-12-05|
    WO2011127414A3|2012-04-19|
    MX2012011678A|2013-03-20|
    US20120006085A1|2012-01-12|
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    法律状态:
    2017-12-19| B07A| Application suspended after technical examination (opinion) [chapter 7.1 patent gazette]|
    2018-07-31| B09A| Decision: intention to grant [chapter 9.1 patent gazette]|
    2018-09-18| B16A| Patent or certificate of addition of invention granted [chapter 16.1 patent gazette]|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 08/04/2011, OBSERVADAS AS CONDICOES LEGAIS. |
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