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SPRAY CASTING (Derleme) Elmas SALAMCI SPREY G.Ü. Fen Bilimleri Dergisi ISSN 1303-9709 G.U. Journal of Science 17(2): 155-173 (2004) 17(2):155-173 (2004) SPRAY CASTING (Derleme) Elmas SALAMCI Zonguldak Karaelmas Üniversitesi, Karabük Teknik Eğitim Fakültesi 78200, Karabük, TÜRKİYE [email protected] ABSTRACT This paper is designed to provide a basic review of spray casting. A brief overview of the historical development of spray casting and the description of plant and equipment have been given. Following metallurgical characteristics of spray formed alloys, process parameters and solidification mechanism of spray deposition have been discussed in detail. Finally, microstructure and mechanical properties of the selected spray cast Al-Zn-Mg-Cu alloys have been presented and compared with conventionally and powder metallurgy processed 7xxx aluminium alloys. Keywords: Spray casting, Osprey, LDC, Al-Zn-Mg-Cu SPREY DÖKÜM (Review) ÖZET Bu makalede sprey döküm yöntemi incelendi. Sprey dökümün özet olarak tarihsel gelişimi ve proses hakkında bilgi verildi. Daha sonra sprey dökümle üretilmiş alaşımların metalurjik özellikleri, proses parametreleri ve sprey döküm yönteminin katılaşma mekanizması detaylı olarak tartışıldı. Son olarak bazı sprey dökülmüş Al-Zn-Mg-Cu alaşımlarının mikroyapı ve mekanik özellikleri verildi ve bu sonuçlar geleneksel döküm yöntemi ve toz metalurjisiyle üretilmiş 7xxx serisi alüminyum alaşımlarının özellikleri ile kıyaslandı. Anahtar Kelimeler: Sprey döküm, Osprey, LDC, Al-Zn-Mg-Cu 1. GİRİŞ 1. INTRODUCTION Hızlı katılaşma yoluyla direk olarak eriyikten alaşım ve Spray forming, spray casting and spray deposition are kompozit malzemelerin üretildiği prosese sprey şekil terms used to describe a process that produces rapidly verme, sprey döküm veya sprey biriktirme yöntemi denir. solidified alloys and composite materials directly from the Bu yöntemde ergimiş metalin atomizasyonu ile üretilen melt. The process involves droplet generation from a damlacıkların püskürtülerek bir kolektör (toplayıcı) stream of molten metal using gas atomisation and the üzerinde toplanması sağlanır. Kolektör üzerinde subsequent deposition of the droplets on a collector. The katılaşarak üretilen bu depozite daha sonra ekstrüzyon, dense preform produced by the droplets can then be dövme veya haddeleme ile şekil verilebilir. Sprey extruded, forged or rolled. There are two potential biriktirme yönteminin iki önemli avantajı vardır. advantages of spray deposition. The major advantage is Bunlardan birincisi eriyikten direk olarak tek bir that a near net shaped product can be produced in a single operasyonla net şekillendirilmiş ürün elde etme imkanıdır. operation, directly from the melt. The process provides Bu yöntem ingot metalurji (İ/M) ve toz metalurji (T/M) significant economic savings by reducing the number of yöntemlerinde uygulanan birçok işlem basamağını processing steps associated with ingot metallurgy (I/M) azaltarak önemli ölçüde ekonomik kazanç sağlar. Net and powder metallurgy (P/M) routes. The main benefits of şekillendirilmiş ürün elde etmenin faydaları şu şekilde near net shape manufacturing processing are (1, 2): sıralanabilir (1, 2): • shorter production time; • Üretim zamanının kısalması • lowered raw material cost; • Hammadde fiyatının düşmesi • reduced energy consumption; • Enerji tüketiminin azalması • improved part performance; • Parça performansının iyileştirilmesi • reduced scrap and handling costs. • Hurda fiyatının azalması 156 G.U. J. Sci., 17(2): 155-173 (2004)/Elmas SALAMCI Sprey şekil verme yönteminin ikinci avantajı metalurjik The second advantage of spray forming is the ve mekanik özelliklerde önemli ölçüde iyileşmenin significant improvement in metallurgical and mechanical sağlanmasıdır. Sprey şekil verme yöntemiyle üretilmiş properties that can be obtained. The microstructures of ürünler ince taneli, alaşım elementleri makroskopik spray formed products are characterised by a uniform segregasyonundan arındırılmış ve düşük oksit içeriklidir distribution of fine grains, no macroscopic segregation of (3-5). alloying elements and a low oxide content (3-5). Sprey şekil verme toz metalurjisi yönteminin birçok Spray forming takes most of the advantages of the avantajına sahipken onun bazı önemli dezavantajlarını powder route, while avoiding some of its major içermez (6-8). Sprey şekil vermenin toz metalurjisine göre disadvantages (6-8). The main advantages of spray temel avantajları şu şekilde sıralanabilir: forming over powder metallurgy are: • Toz metalurjisiyle üretilmiş alüminyum alaşımları • A significant volume fraction of oxides are normally atomize edilmiş tozların yüzeyindeki aluminyum present in PM aluminium alloys due to aluminium hidroksit oluşumundan dolayı önemli miktarda oksit hydroxide formation on the surface of atomised içerir. Bu sprey dökülmüş alaşımlarda azaltılmıştır. powders. This is greatly reduced in spray cast alloys Çünkü işlem koruyucu atmosfer altında kapalı bir because the process is carried out in a closed chamber hücre içinde yürütülmektedir ve hidrojen kapma with a protective atmosphere so that oxygen and minimize edilmiştir. hydrogen pick-up is effectively minimised. • Toz metalurjisinde bulunan ve ürün fiyatını artıran • The various processing steps in the powder route, çok sayıda işlem basamağı sprey şekil verme which increase the product price, are eliminated by yönteminde bulunmamaktadır. spray forming. • Toz metalurjisinde tozların kullanımı ve depolanması • Safety problems that are encountered in the powder esnasında karşılaşılan bazı güvenlik problemleri route are also minimised by eliminating the need for minimize edilmiştir. handling and storing powders. Sprey şekil verilmiş malzemelerde hızlı katılaştırma As a consequence of rapid solidification, the spray sonucunda geleneksel ingot metalurji yönteminde formed materials overcome some problems, such as coarse karşılaşılan kaba taneler ve makrosegregasyona grains and macrosegregation, which are encountered in rastlanmaz. Sprey dökümün ingot metalurjisine göre temel conventional I/M routes. The main advantages of spray avantajları şu şekilde sıralanabilir (9): casting over ingot metallurgy are (9): • Sprey şekil verme ile üretilen alaşımlarda yüksek • Decreased macrosegregation is obtained in spray katılaşma hızından dolayı makrosegregasyon formed alloys, due to a higher rate of solidification. azaltılmıştır. • Finer grains are found in spray formed alloys, which • Sprey şekil verme ile üretilen alaşımlarda mekanik enhance mechanical properties. özelliklerin artmasını sağlayan daha ince taneli yapı • The rapid solidification rate offers increased solid elde edilir. solubility of alloying elements, hence overcoming • Hızlı katılaşmadan dolayı alaşım elementlerinin katı inherent casting problems, such as thermal cracking, çözünürlüğü artırılarak ingot dökülmüş alaşımlarda which is encountered in ingot cast alloys. rastlanan ısıl çatlama gibi döküm problemlerinin Another advantage of spray casting is in the production üstesinden gelinebilir. of composite materials (10-25). The reinforcement or filler Sprey döküm yönteminin bir diğer avantajı kompozit material particles are injected into the atomised stream of malzeme üretimidir (10-25). Sprey dökülmüş kompozit molten metal in the casting chamber to produce spray malzemeler atomize edilen ergimiş metal püskürtülürken formed composite materials. The advantages of this aynı zamanda takviye elemanı sprey içine enjekte edilerek technique over many alternative processes for composite kolektör üzerinde toplanma yoluyla üretilirler. Bu tekniğin manufacture are near net shaped products, significant cost birçok alternatif kompozit üretim yöntemine göre savings, reduced oxidation, refinements in microstructural avantajları net şekillendirilmiş ürün elde edilmesi, önemli features, decreased macrosegregation and elimination of ölçüde fiyat kazancı, azaltılmış oksidasyon, mikroyapısal the extreme thermal excursions which can result in özelliklerin inceltilmesi, azaltılmış makrosegregasyondur degradation of interfacial properties (26, 27). In addition, (26, 27). Ayrıca sprey ile kolektör arasındaki hareketin it is possible to produce different shapes of spray deposit, değiştirilmesiyle bilet, tüp, şerit ve disk gibi değişik such as billets, tubes, strips and discs, by changing the şekilde ürün elde etmek mümkündür. Sprey döküm süper relative movement between the atomised spray and alaşımlardan yüksek hız çeliğine kadar çok çeşitli collector. Spray casting can also be applied to a wide malzemelere uygulanabilir (28-47). variety of materials, from superalloys to high speed Son zamanlarda açıklandığı gibi sprey şekil verme steel/wear resistant alloys (28-47). metodu fiyat açısından etkili, ingot metalurji ve toz It has recently been demonstrated that spray forming is metalurji yöntemine alternatif bir üretim yöntemidir. Bu a cost-effective alternative processing method to çalışmada sprey dökülmüş 7xxx serisi alüminyum conventional ingot technology and to powder metallurgy. alaşımlarının mikroyapı ve mekanik özellikleri, ingot In this study, structure and mechanical properties of spray metalurji ve toz metalurjisi yöntemiyle üretilmiş 7xxx deposited 7xxx series Al alloys were compared to ingot serisi alüminyum alaşımlarının özellikleri ile metallurgy and powder metallurgy processed 7xxx Al kıyaslanmıştır. Bu çalışma sprey şekil verme ile üretilmiş alloys. This study indicates that spray formed alloys have a alaşımların ince tane, homojen mikroyapı, mükemmel fine grained, uniform microstructure and an excellent tokluk ve mukavemet bileşimine
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