System and method to stabilize transition metal precipitates in cast aluminum alloys during primary solidification

Abstract

A system for casting an aluminum alloy includes a first chamber for containing a first melt at a first temperature, a second chamber for containing second melt at a second temperature that is lower than the first temperature, a mixing chamber in communication with the first chamber and the second chamber for simultaneously receiving and mixing the first melt from the first chamber with the second melt from the second chamber, and a mold chamber in communication with the mixing chamber and for receiving the mixed melt.

What is claimed is: 
     
         1 . A system for casting an aluminum alloy comprising:
 a first chamber for containing a first melt at a first temperature;   a second chamber for containing second melt at a second temperature that is lower than the first temperature;   a mixing chamber in communication with the first chamber and the second chamber for simultaneously receiving and mixing the first melt from the first chamber with the second melt from the second chamber; and   a mold chamber in communication with the mixing chamber and for receiving the mixed melt.   
     
     
         2 . The system of  claim 1 , wherein the first melt comprises Aluminum and at least one peritectic transition metal element. 
     
     
         3 . The system of  claim 1 , wherein the first melt comprises one of Zirconium, Scandium, Cobalt, Chromium, Niobium, Tantalum, Titanium, Vanadium, Tungsten, Molybdenum, Hafnium and Boron. 
     
     
         4 . The system of  claim 1 , wherein the second melt has a composition that includes a higher percentage of Silicon than the first melt. 
     
     
         5 . The system of  claim 1 , wherein the second melt has a composition that includes a higher percentage of Copper than the first melt. 
     
     
         6 . The system of  claim 1 , wherein the second melt has a composition that includes a higher percentage of Magnesium than the first melt. 
     
     
         7 . The system of  claim 1 , wherein the first temperature is higher than the liquidus temperature of an aluminum precipitate in the first melt and the second temperature is lower than the liquidus temperature of the aluminum precipitate in the first melt and above the liquidus temperature of the mixed melt. 
     
     
         8 . The system of  claim 1 , wherein the first temperature is higher than the liquidus temperature of an aluminum precipitate in the first melt and the second temperature is lower than the liquidus temperature of the aluminum precipitate in the first melt and below the liquidus temperature of the mixed melt. 
     
     
         9 . The system of  claim 7 , wherein the aluminum precipitate comprises at least one of an Aluminum-Vanadium precipitate, an Aluminum-Zirconium precipitate, an Aluminum-Titanium precipitate, an Aluminum-Scandium precipitate, an Aluminum-Cobalt precipitate, an Aluminum-Chromium precipitate, an Aluminum-Niobium precipitate, and Aluminum-Tantalum precipitate, and Aluminum-Tungsten precipitate, an Aluminum-Molybdenum precipitate, an Aluminum-Hafnium precipitate, and an Aluminum-Boron precipitate. 
     
     
         10 . A method of casting an aluminum alloy, comprising:
 providing a first melt at a first temperature in a first chamber;   providing a second melt at a second temperature that is lower than the first temperature in a second chamber;   mixing the first melt and the second melt in a mixing chamber to form a mixed melt;   flowing the mixed melt into a mold chamber; and   solidifying the mixed melt in the mold chamber.   
     
     
         11 . The method of  claim 10 , wherein the first melt comprises Aluminum and at least one peritectic transition metal element. 
     
     
         12 . The method of  claim 10 , wherein the first melt comprises one of Zirconium, Scandium, Cobalt, Chromium, Niobium, Tantalum, Titanium, Vanadium, Tungsten, Molybdenum, Hafnium and Boron. 
     
     
         13 . The method of  claim 10 , wherein the second melt has a composition that includes a higher percentage of Silicon than the first melt. 
     
     
         14 . The method of  claim 10 , wherein the second melt has a composition that includes a higher percentage of Copper than the first melt. 
     
     
         15 . The method of  claim 10 , wherein the second melt has a composition that includes a higher percentage of Magnesium than the first melt. 
     
     
         16 . The method of  claim 10 , wherein the first temperature is higher than the liquidus temperature of an aluminum precipitate in the first melt and the second temperature is lower than the liquidus temperature of the aluminum precipitate in the first melt and above the liquidus temperature of the mixed melt. 
     
     
         17 . The method of  claim 10 , wherein the first temperature is higher than the liquidus temperature of an aluminum precipitate in the first melt and the second temperature is lower than the liquidus temperature of the aluminum precipitate in the first melt and below the liquidus temperature of the mixed melt. 
     
     
         18 . The method of  claim 16 , wherein the aluminum precipitate comprises at least one of an Aluminum-Vanadium precipitate, an Aluminum-Zirconium precipitate, an Aluminum-Titanium precipitate, an Aluminum-Scandium precipitate, an Aluminum-Cobalt precipitate, an Aluminum-Chromium precipitate, an Aluminum-Niobium precipitate, and Aluminum-Tantalum precipitate, and Aluminum-Tungsten precipitate, an Aluminum-Molybdenum precipitate, an Aluminum-Hafnium precipitate, and an Aluminum-Boron precipitate.