Aluminum castings using ultrasonic technology

Abstract

A ladle, process, and system for casting an aluminum-based alloy includes a casting ladle. The casting ladle includes a cup and the cup defines an opening. The ladle also includes an ultrasonic transducer including an end immersed in the cup, wherein the cup exhibits a first depth and the ultrasonic transducer is immersed in the cup at a second depth in a range of 5 percent to 100 percent of the first depth. An aluminum-based alloy melt is introduced into an opening of a casting ladle, an ultrasonic transducer immersed in the aluminum-based alloy melt is activated, and the aluminum-based alloy melt is transferred onto a casting surface.

What is claimed is: 
     
         1 . A ladle for casting an aluminum-based alloy, comprising:
 a casting ladle, the casting ladle including a cup, the cup defining an opening; and   an ultrasonic transducer including an end immersed in the cup, wherein the cup exhibits a first depth and the ultrasonic transducer is immersed in the cup at a second depth in a range of 5 percent to 100 percent of the first depth.   
     
     
         2 . The ladle of  claim 1 , wherein the cup is defined by a ladle wall and the ultrasonic transducer does not directly contact the ladle wall. 
     
     
         3 . The ladle of  claim 1 , wherein the cup is defined by a ladle wall, further comprising a bracket connected to the ladle wall, wherein the ultrasonic transducer is connected to the bracket. 
     
     
         4 . The ladle of  claim 3 , wherein the bracket defines an aperture and the ultrasonic transducer is positioned in the aperture. 
     
     
         5 . The ladle of  claim 1 , wherein the ultrasonic transducer is secured to a robot arm movable relative to the opening defined in the cup. 
     
     
         6 . The ladle of  claim 5 , wherein the robot arm is connected to the casting ladle. 
     
     
         7 . A process of casting an aluminum-based alloy, comprising:
 introducing an aluminum-based alloy melt into an opening of a casting ladle, wherein the casting ladle includes a cup for receiving the aluminum-based alloy melt and the cup exhibits a first depth;   activating an ultrasonic transducer immersed in the aluminum-based alloy melt, wherein the ultrasonic transducer is immersed through the opening to a second depth in a range of 5 percent to 100 percent of the first depth of the cup; and   transferring the aluminum-based alloy melt onto a casting surface.   
     
     
         8 . The process of  claim 7 , wherein the ultrasonic transducer is activated for a time period in the range of 5 second to 40 seconds. 
     
     
         9 . The process of  claim 7 , further comprising applying power to the ultrasonic transducer at levels in a range of 1 kilowatt to 10 kilowatts, at a power density in a range of 10 watts per square centimeter to 500 watts per square centimeter, and at a frequency in a range of 10 kilohertz to 100 kilohertz. 
     
     
         10 . The process of  claim 7 , further comprising deactivating the ultrasonic transducer prior to transferring the aluminum-based alloy melt onto the casting surface. 
     
     
         11 . The process of  claim 7 , wherein the ultrasonic transducer is immersed in the casting ladle prior to introducing the aluminum-based alloy melt into the opening of the casting ladle. 
     
     
         12 . The process of  claim 7 , wherein the ultrasonic transducer is immersed into the casting ladle by a robot arm after the aluminum-based alloy melt is introduced into the casting ladle. 
     
     
         13 . The process of  claim 7 , wherein the casting surface is a mold cavity. 
     
     
         14 . The process of  claim 7 , wherein the casting surface is a belt. 
     
     
         15 . A system for casting an aluminum-based alloy, comprising:
 a casting surface for receiving an aluminum-based alloy melt; and   a casting ladle for transferring the aluminum-based alloy melt onto the casting surface, the casting ladle including a cup, the cup defining an opening, and an ultrasonic transducer including an end immersed in the cup through the opening, wherein the cup exhibits a first depth and the ultrasonic transducer is immersed in the cup at a second depth in a range of 5 percent to 100 percent of the first depth.   
     
     
         16 . The system of  claim 15 , wherein the casting surface includes a mold cavity. 
     
     
         17 . The system of  claim 15 , wherein the casting surface includes a belt. 
     
     
         18 . The system of  claim 15 , further comprising a power supply and a controller operatively coupled to the ultrasonic transducer. 
     
     
         19 . The system of  claim 15 , wherein the cup is defined by a ladle wall, further comprising a bracket connected to the ladle wall, wherein the ultrasonic transducer is connected to the bracket. 
     
     
         20 . The system of  claim 15 , wherein the ultrasonic transducer is secured to a robot arm and the robot arm is movable relative to the opening defined in the cup.