Process for Producing Formed Parts

Abstract

A process for producing formed parts made of an aluminum alloy, including the steps of exposing the aluminum alloy to high shearing forces in a mixing and kneading machine, feeding the liquid aluminum alloy to the working space at one end of the housing and, at the other end of the housing, removing from the working space the liquid aluminum alloy now formed as a partially solid aluminum alloy with a predefined solids content, and processing the partially solid aluminum alloy with the predefined solids content into formed parts, wherein the solids content of the aluminum alloy in the working space is set to the predefined solids content by cooling and heating the working space in a targeted manner. The mixing and kneading machine includes a housing with a working space, a worm shaft including kneading blades and axial passage openings, and kneading projections.

1 . A process for producing formed parts made of an aluminum alloy, comprising the steps of:
 (a) exposing the aluminum alloy to high shearing forces in a mixing and kneading machine, wherein the mixing and kneading machine comprises: a housing with a working space that is surrounded by an inner housing sleeve, a worm shaft that rotates about a longitudinal axis and oscillates along the longitudinal axis in the inner housing sleeve and is interrupted circumferentially to create individual kneading blades, axial passage openings defined between the kneading blades, and kneading projections that project from the inner housing sleeve, protrude into the working space, and pass through the axial passage openings,   (b) feeding liquid aluminum alloy to the working space at one end of the housing,   (c) at the other end of the housing, removing from the working space the liquid aluminum alloy as a partially solid aluminum alloy with a predefined solids content, and   (d) processing the partially solid aluminum alloy with the predefined solids content into formed parts, wherein the solids content of the aluminum alloy in the working space is set to the predefined solids content by cooling and heating the working space in a targeted manner.   
     
     
         2 . The process as claimed in  claim 1 , wherein the formed parts have at least one dimension greater than 0.5 m, and at least one area with a wall thickness of 1 to 4 mm. 
     
     
         3 . The process as claimed in  claim 1 , further comprising the steps of:
 (e) transferring the partially solid aluminum alloy into a filling chamber of a die casting machine and   (f) introducing the partially solid aluminum alloy into a casting mold with a piston to form a die cast part.   
     
     
         4 . The process as claimed in  claim 1 , further comprising the step of:
 (e) transferring the partially solid aluminum alloy into a die of a forging press to form a forged part.   
     
     
         5 . The process as claimed in  claim 1 , wherein the inner housing sleeve is surrounded by a outer housing sleeve such that an intermediate space is formed, and cold, hot, or cold and hot gases are conducted through the intermediate space for cooling, and heating the working space. 
     
     
         6 . The process as claimed in  claim 5 , wherein the inner housing sleeve and the outer housing sleeve with the intermediate space is divided along the circumference in at least two segments, along the longitudinal axis in at least two segments or along the circumference and longitudinal axis in at least two segments, respectively, thereby creating individual compartments providing separate heating channels. 
     
     
         7 . The process as claimed in  claim 5 , wherein further comprising the steps of:
 (e) conducting air through the intermediate space and the segments for cooling, and   (f) conducting hot gases through the intermediate space and the segments or placing electric resistance elements within the intermediate space and the segments for heating.   
     
     
         8 . The process as claimed in  claim 7 , wherein the gases are conducted through the intermediate space and the segments in current or countercurrent to the direction in which the aluminum alloy is transported. 
     
     
         9 . The process as claimed in  claim 1 , further comprising the step of
 (e) in order to set a desired solids content, measuring and setting the viscosity of the aluminum alloy in the working space to a predefined value by cooling and heating the working space in a targeted manner.   
     
     
         10 . The process as claimed in  claim 1 , wherein the solids content of the aluminum alloy is set to 40 to 80%. 
     
     
         11 . The process as claimed in  claim 1 , further comprising the steps of:
 (e) removing the partially solid aluminum alloy from the working space as a partially solid metal strand,   (f) splitting the partially solid metal strand is split into partially solid metal portions, and   (g) transferring the partially solid metal portions into the filling chamber of the die casting machine.   
     
     
         12 . The process as claimed in  claim 1 , further comprising the steps of:
 (e) in order to produce formed parts reinforced with particles in the nano or micron to multi-micron scale, mixing particles with the aluminum alloy and finely dispersing the particles in the aluminum alloy using high shearing forces in the mixing and kneading machine,   (f) feeding liquid aluminum alloy and particles are fed to the working space at one end of the housing and   (g) removing the liquid aluminum alloy and particles, now formed as partially solid aluminum alloy with a predefined solids content and with particles finely dispersed in the aluminum alloy, from the work space at an opposite end of the housing.   
     
     
         13 . The process as claimed in  claim 12 , wherein the content of the particles in the alloy is 0.1 to 10% by volume. 
     
     
         14 . The process as claimed in  claim 13 , wherein the particles in the nano scale used are fumed silica, carbon nanotubes (CNT) and also further, nano scale particles of metal and semimetal oxides, and nano scale particles of metals dissolving slowly to infinitely slowly in aluminum. 
     
     
         15 . The process as claimed in  claim 13 , wherein the particles in the micron to multi-micron scale used are particles of metal and semimetal oxides, carbides, borides or nitrides, and nano scale particles of metals dissolving slowly to infinitely slowly in aluminum. 
     
     
         16 . (canceled) 
     
     
         17 . The process as claim in  claim 2 , wherein the formed parts have at least one dimension greater than 1 m, and at least one area with a wall thickness of 1 to 2 mm. 
     
     
         18 . The process as claimed in  claim 5 , wherein the intermediate space is formed as a hollow cylinder. 
     
     
         19 . The process as claimed in  claim 10 , wherein the solids content of the aluminum alloy is set to 50% or greater. 
     
     
         20 . The process as claimed in  claim 14 , wherein the nano scale particles of metal and semimetal oxides include aluminum oxide (Al 2 O 3 ), titanium dioxide (TiO 2 ), zirconium oxide (ZrO 2 ), antimon (III) oxide, chromium (III) oxide, iron (III) oxide, germanium (IV) oxide, vanadium (V) oxide or tungsten (VI) oxide, and nano scale particles of metals dissolving slowly to infinitely slowly in aluminum, such as tungsten, molybdenum and rare earth metals. 
     
     
         21 . The process as claimed in  claim 15 , wherein the particles of metal and semimetal oxides, carbides, borides or nitrides include aluminum oxide (Al 2 O 3 ), titanium dioxide (TiO 2 ), zirconium oxide (ZrO 2 ), antimony (III) oxide, chromium (III) oxide, iron (III) oxide, germanium (IV) oxide, vanadium (V) oxide or tungsten (VI) oxide, silicon carbide, tungsten carbide, nickel boride, titanium boride and tungsten carbide, and the nano scale particles of metals dissolving slowly to infinitely slowly in aluminum, include tungsten, molybdenum and rare earth metals. 
     
     
         22 . A formed part made from a process comprised of the following steps:
 (a) exposing the aluminum alloy to high shearing forces in a mixing and kneading machine, wherein the mixing and kneading machine comprises: a housing with a working space that is surrounded by an inner housing sleeve, a worm shaft that rotates about a longitudinal axis and oscillates along the longitudinal axis in the inner housing sleeve and is interrupted circumferentially to create individual kneading blades, axial passage openings defined between the kneading blades, and kneading projections that project from the inner housing sleeve, protrude into the working space, and pass through the axial passage openings,   (b) feeding liquid aluminum alloy to the working space at one end of the housing,   (c) at the other end of the housing, removing from the working space the liquid aluminum alloy as a partially solid aluminum alloy with a predefined solids content, and   (d) processing the partially solid aluminum alloy with the predefined solids content into formed parts, wherein the solids content of the aluminum alloy in the working space is set to the predefined solids content by cooling and heating the working space in a targeted manner.