[China Aluminum Network] Today, aluminum ingot forging technology usually uses casting technology, that is, the aluminum liquid is poured directly into the mold, and is removed after cooling. The quality of the product is primarily in this process, and all forging techniques are based on this process. The forging process is a physical process in which liquid aluminum cools and crystallizes into solid aluminum ingots. 1. Continuous casting Continuous casting can be divided into two methods: mixing furnace casting and external casting. Both use continuous forging machines. Mixing furnace casting is the casting of molten aluminum into a mixing furnace followed by casting by a mixing furnace, primarily for the production of remelted aluminum ingots and forged alloys. Outer casting is performed by lifting the bag directly to the forging machine. The main reason is that the forging equipment can not be produced satisfactorily, or the quality of the incoming material can not be directly introduced into the furnace. Because there is no external heating source, the demand for the bag has a certain temperature, usually summer at 690 ~ 740 °C, winter in the 700 ~ 760 °C, to ensure that the aluminum ingot to obtain a better appearance. Mixing furnace casting, first through the ingredients, and then poured into the mixing furnace, mixing evenly, then participate in the essence of flux. Casting alloy ingots must be clarified for more than 30 minutes. When casting, the furnace hearth of the mixing furnace is aligned with the second and third casting molds of the forging machine, which ensures the fluid flow changes and has certain maneuverability during mold changing. Furnace and forging machine are connected by runners, and the runners are shorter, which can reduce the oxidation of aluminum and avoid the formation of vortexes and splashes. When the forging machine is deactivated for more than 48 hours, the mold is to be preheated for 4 hours before being restarted. The aluminum liquid flows into the mold through the flow cell, and the oxide film on the surface of the aluminum liquid is removed with a shovel, which is called a slag. After a full mold is reached, the runner is moved to the next mold. The forging machine travels in succession. The molds proceed in sequence, and the aluminum liquid is gradually cooled. When the middle of the forging machine is reached, the aluminum liquid is condensed into aluminum ingots, and the printer prints the melting number. When the aluminum ingot reaches the top of the forging machine, it is now completely condensed into aluminum ingots. At this point, the mold is turned over, the aluminum ingot is ejected from the mold, and it falls on the active car feeder, and is automatically stacked and bundled by the stacker. Aluminum ingots. The forging machine is cooled by spray water, but it is necessary to supply water after the forging machine has been turned full circle. About 8 to 10 tons of water is consumed per ton of liquid aluminum, and it is necessary to have a hair dryer for cooling in the summer. Casting ingots are cast in a flat mold. The direction of condensation of the molten aluminum is from bottom to top, and the center of the upper part condenses, resulting in a groove-shaped depression. The setting time and conditions of each part of the aluminum ingot are not the same, so the chemical composition will also be different, but it is in line with the specification as a whole. Disadvantages of remelting aluminum ingots are: 1 porosity. The main reason is that the casting temperature is too high, the aluminum liquid contains more gas, the surface of the aluminum ingot has more pores (pinholes), and the appearance of the aluminum ingot is dark, and hot cracking occurs during severe conditions. 2 slag inclusions. The first reason is that the first is that the slag is not clean and it constitutes slag inclusion; the second is that the temperature of the aluminum liquid is too low to constitute an internal slag. 3 Ripples and flashes. The first is that the operation is not precise, the aluminum ingot is too large, or the running of the casting machine is not smooth. 4 cracks. Cold cracking is the main reason that the casting temperature is too low, which results in the crystallization of aluminum ingots that are not dense, and even loose and even cracks. Hot cracks are caused by high casting temperatures. 5 component segregation. The main reason is that the mixing is not uniform when forging the alloy. 2. Vertical semi-continuous forging Vertical semi-continuous forging is mainly used for the production of aluminum ingots, ingots, and various deformed alloys for processing profiles. The aluminum liquid is poured into the mixing furnace after being compounded. Because of the special requirements of the wire, the center-joint Al-B must be taken out of the center to remove titanium and vanadium (line ingot) from the aluminum liquid before forging; the ingot needs to participate in the Al-Ti--B alloy. (Ti5%B1%) for refinement. Make appearance arrangements more detailed. High-magnesium alloy plus 2 # essence agent, the amount of 5%, mixing evenly, after standing for 30min to remove scum, you can cast. The forging machine chassis is raised prior to casting and the water on the chassis is blown with compressed air. Then raise the chassis into the crystallizer, apply a layer of smooth oil to the inner wall of the crystallizer, put some cooling water into the water jacket, put the pre-heated distribution plate, the active conditioning plug and the flow cell, and make the distribution plate The mouth is located in the center of the crystallizer. At the beginning of the casting, press the active conditioning plug with your hand to block the flow nozzle, cut the opening of the mixing furnace, allow the aluminum liquid to flow into the distribution plate through the flow cell, and wait until the molten aluminum reaches 2/5 in the distribution tray. Condition the stopper so that the liquid flows into the mold and the liquid melts on the chassis. When the molten aluminum reaches 30mm high in the crystallizer, the bottom plate can be lowered and the cooling water can be sent at the beginning. The active conditioning plug controls the molten aluminum to flow into the crystallizer in a balanced manner, and the molten aluminum in the crystallizer remains unchanged. The scum and oxide film on the surface of the aluminum liquid must be promptly removed. When the length of the aluminum ingot is about 6m, the furnace eye is blocked, the distribution plate is removed, the water is stopped after the aluminum liquid is completely condensed, the water jacket is removed, and the cast aluminum ingot is taken out by a monorail crane, and the scale is required on the sawing bed. Saw off and prepare for the next casting. During casting, the temperature of the aluminum liquid in the mixing furnace is maintained at 690 to 710° C. The temperature of the aluminum liquid in the distribution pan is maintained at 685-690° C., the forging speed is 190 to 21 Omm/min, and the cooling water pressure is 0.147 to 0.196 MPa. The forging speed is proportional to the square wire ingot: VD=K Where V is the forging speed, mm/min or m/h; D is the side length of the ingot, mm or m; K is the constant, m2/h, usually 1.2 to 1.5. The vertical half-sequential forging is a sequential crystallization method. After the molten aluminum enters the cast hole, the open end crystallizes on the chassis and the inner wall of the crystallizer. Because the cooling conditions of the center and the edge are not the same, the crystals form a low center and a high periphery. The chassis is lowered at a constant speed. The upper part is continuously injected with aluminum liquid, so that there is a semi-condensation zone between the solid aluminum and the liquid aluminum. Because the aluminum liquid needs to be shortened during the condensation, a smooth oil is added to the inner wall of the crystallizer, and the aluminum is condensed as the chassis is lowered. Exit the crystallizer, and there is a circle of cooling water eyes in the lower part of the crystallizer. The cooling water can be sprayed onto the surface of the aluminum ingot that has been pulled out, and is used for secondary cooling until the ingot finish casting is stopped. Sequential crystallization can establish relatively satisfactory coagulation conditions, and the crystallized grain size, mechanical properties, and electrical conductivity are all favorable. There is no difference in mechanical properties in the height direction of the cast ingot, the segregation is smaller, the cooling rate is faster, and a very fine crystallographic arrangement can be achieved. Aluminium wire ingot should be flat and smooth with no inclusions, cracks, pores, etc. The external crack length should not exceed 1.5mm. The appearance of slag and edge cracks should not exceed 2mm. There should be no cracks, air holes, and slag inclusions. There are no more than 5 slag inclusions in lmm. The main disadvantages of aluminum ingots are: 1 crack. The reason is that the temperature of aluminum liquid is too high, the speed is too fast, and the residual stress is increased; the aluminum liquid contains more than 0.8% of silicon, generates aluminum silicon and the same melt, and then generates a certain free silicon, increasing the thermal cracking of the metal: Or lack of cooling water. When the surface of the crystallizer is rough or no smooth oil is used, the outer surface and corners of the ingot also crack. 2 slag inclusions. The inclusion of slag on the outer surface of the aluminum wire ingot is due to the fact that the aluminum liquid fluctuates, the oxide film on the surface of the aluminum liquid breaks, and the surface scum enters the side surface of the ingot. Sometimes smooth oil can also bring in some slag. The internal slag inclusions are due to the low temperature of the liquid aluminum, the large viscosity, the slag cannot be floated in time, or the aluminum liquid surface frequently changes during casting. 3 cold separated. The main reason for the formation of cold septa is that the level of aluminum liquid in the mold is excessively shaken, the casting temperature is low, the ingot speed is too slow or the forging machine vibrates, and the inconsistency results in 4 porosity. The pores referred to here are small pores with a diameter of less than 1 mm. The reason for this is that the casting temperature is too high, and the condensation is too fast, so that the gas contained in the aluminum liquid cannot escape in time. After condensation, the gas bubbles are accumulated in the ingot to form pores. 5 rough appearance. Because the inner wall of the crystallizer is not smooth, the smooth effect is not good, and when it is severe, the aluminum tumor of the crystal appearance is formed. Or because the ferro-silicon ratio is too large, the uneven appearance of cooling occurs. 6 leak aluminum and re-analysis. The first is operational issues, and the harsh ones also constitute tumors. 3. Ensure the quality of the ingot (1) Aluminum ingot for remelting. The more important technical condition in the ingot process is the casting temperature. It is necessary to strictly control the casting temperature during the casting process, and is usually higher than the coagulation temperature of the aluminum liquid by 30 to 50°C. (2) Ingots. The casting of wire ingots is a bit more complicated and the conditions to be manipulated are the ingot speed. The ingot speed is related to the ingot diameter. The casting temperature adheres to 680-690°C, the cooling water pressure is 0.147-0.196MPa, and the aluminum liquid level in the inner wall of the mold is controlled at about 30mm. To control the above conditions and strengthen the operation, you can get better quality.
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