Shape Flow Casting and In-rotating-liquid-spinning Processes for the Continuous Production of Wires and of High-strength and Soft Magnetic Metallic Fibres

Computer-controlled facilities for continuous casting of metallic fibres and wires performing in-rotating- liquid-spinning (INROLISP) and shape flow casting (SFC) were designed and installed to determine and control the near-net-shape casting processes over an extended production period. In particular, the flow behaviour of the melt jet was experimentally investigated and theoretically described using fluid dynamic equations. The controlling process parameters, such as the velocity of the melt jet, the stable free flight length, the nozzle geometry and cooling rate, were examined and optimised. Several pure metals as well as microcrystalline and amorphous alloys were cast into continuous fibres and wires of high quality. Microstructural features and mechanical properties of rapidly quenched fibres and thin wires were also evaluated. Of great potential application is the production of amorphous softmagnetic Fe base and Co base thin wires with diameters of about 30 to 50 μm. These microwires are used as sensor cores in highly sensitive novel magnetic field sensors based on a magneto-electric effect.Direct casting of wires with diameters up to 3 mm is carried out using the shape flow casting technique. The SFC facility is an highly instrumented modified meltspin facility, performing rapid substrate quenching. The process principles of the SFC technology, which enable a flexible production of steel, nickel base alloy wires and other novel materials are presented. The microstructural features are correlated with the process parameters.