Equipment and process for producing cast aluminum-magnesium alloy

Abstract

The invention discloses equipment and a process for producing a cast aluminum-magnesium alloy, and relates to the technical field of metal material casting, the equipment comprises a smelting unit, a casting unit and a demolding unit; according to the smelting unit, the alloy purity is improved through a resistance-type smelting furnace capable of accurately controlling the temperature, a rotary blowing device capable of efficiently degassing and the like; the casting unit optimizes the casting quality by using a magnetorheological fluid coating mold and an electromagnetic regulation and control device; the demolding unit reduces casting damage by means of multiple cooperative demolding means; the process comprises the steps of raw material pretreatment, precise smelting, precise casting, reasonable demolding and the like. By means of the means, the problems that in a traditional technology, gas purification is not thorough, the casting process is difficult to control, and parts are prone to being damaged during demolding are effectively solved, the functions of improving the quality of aluminum magnesium alloy castings, improving the production efficiency and reducing the rejection rate are achieved, and remarkable economic and technical benefits are achieved.

Description

Technical Field

[0001] The present invention relates to the technical field of metal material casting, in particular to equipment and a process for producing cast aluminum-magnesium alloy. Background Art

[0002] Numerous problems exist in the traditional aluminum-magnesium alloy casting process. During the melting stage, imprecise temperature control leads to alloy composition deviations, and incomplete gas purification leaves harmful gases and impurities that affect alloy properties. During the casting stage, precise control of the casting process is difficult, leading to defects such as shrinkage cavities and porosity in the castings, and dimensional accuracy is difficult to ensure. During the demolding stage, the demolding process can easily damage the casting surface, affecting product yield. Furthermore, the entire production process is inefficient, making it difficult to meet the demands of large-scale, high-quality production.

[0003] In view of this, this application is hereby filed. Summary of the Invention

[0004] The purpose of the present invention is to provide an apparatus and process for producing cast aluminum-magnesium alloys to solve the problems mentioned in the above background technology.

[0005] In order to solve the above technical problems, the present invention provides an apparatus for producing cast aluminum-magnesium alloy, comprising:

[0006] The melting unit is equipped with a resistance melting furnace, a PID temperature control system (accuracy ±5°C), a 360° rotating rotary injection device (argon flow rate 0-20 L / min, pressure 0-0.5 MPa), an automated refining flux addition system (accuracy ±0.1 kg, hopper capacity 200 kg), and a multi-layer filter system (pore size 50 μm → 20 μm → 5 μm). The resistance melting furnace, combined with a high-precision PID temperature control system, precisely controls the melting temperature, ensuring a stable melting temperature for the aluminum-magnesium alloy raw materials. This reduces alloy composition deviations caused by temperature fluctuations and improves alloy quality stability. The 360° rotating rotary injection device, combined with adjustable argon flow and pressure, effectively and comprehensively removes gaseous impurities from the alloy liquid, enhancing alloy purity. The automated refining flux addition system ensures precise refining flux addition, and the large 200 kg hopper reduces frequent refilling operations, improving production efficiency. The multi-layer filter device is designed with apertures from large to small, which can effectively intercept impurities of different particle sizes, further purify the gas generated by smelting, reduce environmental pollution, and improve alloy quality;

[0007] Casting unit: It includes a casting mold coated with a 0.5mm magnetorheological fluid coating, and an electromagnetic control device consisting of a 10kW electromagnetic generator (magnetic field strength 0-3T) and a PLC controller; the magnetorheological fluid coating coated on the surface of the casting mold can change its rheological properties in real time according to the different stages of the casting process under the action of the electromagnetic control device. The viscosity is reduced during the filling stage so that the alloy liquid can smoothly fill the mold cavity, improve the filling quality, and reduce internal defects in the casting; the viscosity is increased during the solidification stage to inhibit the flow of the alloy liquid, effectively reduce defects such as shrinkage cavities and shrinkage, and significantly improve the quality of the casting. The electromagnetic control device, consisting of a 10kW electromagnetic generator and a PLC controller, can accurately control the magnetic field strength and output time, achieve precise control of the magnetorheological fluid coating, and ensure the stability and consistency of the casting process;

[0008] The demolding unit includes an electrostatic sprayer (spraying pressure 0.1-0.3 MPa, thickness control 0.05 mm), a hydraulic demolding machine (demolding force 0-50 kN), a vibration demolding device (frequency 10-50 Hz, amplitude 0.1-1 mm), and a thermal expansion and contraction platform (temperature ramp rate 5°C / s). The electrostatic sprayer evenly applies the release agent to the mold surface, precisely controlling the spray pressure and thickness to ensure a uniform and effective demolding lubricant film, minimizing damage to the casting surface during demolding and improving product yield. The hydraulic demolding machine flexibly adjusts the demolding force within a range of 0-50 kN to ensure a smooth demolding process, depending on the specific requirements of the casting. The vibration demolding device and the thermal expansion and contraction platform work together to assist in demolding through vibration and temperature fluctuations, further reducing demolding difficulty, minimizing deformation or damage to the casting caused by improper demolding, and improving demolding efficiency and product quality.

[0009] Furthermore, the melting furnace's temperature sensor must be calibrated using a standard thermometer before each use, with deviations controlled within ±2°C. At least five temperature monitoring points are located within the furnace to ensure comprehensive and accurate temperature monitoring. Using a standard thermometer to calibrate the furnace's temperature sensor and control deviations within a very small range further improves temperature measurement accuracy, providing a more reliable temperature basis for alloy smelting. Setting at least five temperature monitoring points within the furnace allows for comprehensive temperature monitoring at different locations within the furnace, enabling timely detection of temperature unevenness and preventing local temperature anomalies from affecting alloy smelting, thereby ensuring uniformity of alloy composition and quality stability.

[0010] Furthermore, the rotary blowing device is tested for sealing using a soapy water leak detection method before commissioning, with a leakage rate of ≤0.5%. The blowing head is made of a high-temperature, corrosion-resistant nickel-based alloy to ensure long-term stable operation. Using this method before commissioning the rotary blowing device can effectively detect sealing problems with the device and control the leakage rate to an extremely low level, ensuring the stability and reliability of the argon blowing process and avoiding poor degassing effects due to gas leakage. The blowing head is made of a high-temperature, corrosion-resistant nickel-based alloy, enabling it to operate stably for a long time in high-temperature, highly corrosive smelting environments, reducing equipment maintenance and replacement frequency, lowering production costs, and improving production efficiency.

[0011] Furthermore, the refining flux addition equipment is equipped with an electronic scale calibration module, calibrated with standard weights to an error of ≤0.1%. It also features an automatic cleaning device that automatically removes residual refining flux after each addition, preventing cross-contamination. The electronic scale calibration module, calibrated with standard weights, ensures high precision in the amount of refining flux added and an accurate ratio of refining flux to alloy liquid, effectively maximizing the refining flux's effectiveness and enhancing alloy refining results. The automatic cleaning device automatically removes residual refining flux after each addition, preventing cross-contamination between different batches of refining flux, ensuring purity and consistency throughout each refining process, and further improving alloy quality.

[0012] Furthermore, the release agent spraying device is provided with a viscosity detection module (accuracy ±2mPa·s) and a batch management module. Different batches of release agents must be tested and verified to be qualified before use, and the spray gun of the spraying device can be rotated 360 degrees to ensure uniform spraying on the mold surface; the viscosity detection module of the release agent spraying device can monitor the viscosity of the release agent in real time to ensure that it is within the appropriate range and to ensure the stability of the performance of the release agent. The batch management module and the trial spray verification link can effectively avoid the problem of unstable demoulding effect caused by batch differences of release agents and improve the consistency of product quality. The spray gun can rotate 360 degrees and can cover the mold surface in all directions to achieve uniform spraying, so that the release agent forms a uniform lubricating film on the mold surface, reducing the difficulty of demoulding, reducing damage to the casting surface, and improving the product yield.

[0013] A process for producing a cast aluminum-magnesium alloy comprises the following steps:

[0014] Melting stage: The pretreated raw materials are added in batches to a melting furnace preheated to 100°C (50-100kg per charge, with a 5-minute interval). The temperature is raised to 750°C at a rate of 10°C / min with stirring (stirring for 1 minute every 10 minutes, at a speed of 50 rpm). After melting, argon is injected for degassing (flow rate 10 L / min, pressure 0.2 MPa, time 20 minutes), and a 1.5% by weight refining agent is added (stirring at 200 rpm for 10 minutes). Finally, the gas is filtered for 15 minutes (the filter pressure difference is less than 0.1 MPa). After pretreatment, the raw materials are added in batches to the preheated melting furnace. Controlling the feeding amount and interval time ensures uniform heating of the raw materials within the furnace, accelerating melting and improving melting efficiency. A steady heating rate and intermittent stirring promote uniform mixing of the alloy components. Steps such as argon degassing, adding refining agents and stirring the reaction, as well as gas filtering, can effectively remove gases and impurities in the alloy liquid, improve the alloy purity, and thus enhance the mechanical properties and quality stability of the castings.

[0015] Casting stage: The casting system is preheated to 200°C (keep warm for 30 minutes), and a heated transfer bag is used to transfer the alloy liquid (temperature drop ≤ 10°C). The flow rate is controlled at 6-7kg / s by a flow sensor; the PLC is started 3 seconds before filling, the magnetic field in the filling stage is 0.3T (lasting 5 seconds), and the magnetic field in the solidification stage is 1.5T (lasting 30 minutes), the mold cooling rate is 5°C / min, and the temperature uniformity is ±5°C; preheating and keeping the casting system warm, and using a heated transfer bag to transfer the alloy liquid can reduce the temperature loss of the alloy liquid during the transfer and casting process, ensure the fluidity of the alloy liquid, and facilitate the smooth filling process. The flow rate is precisely controlled by the flow sensor, and the appropriate magnetic field strength is applied at different stages by combining the PLC to control the electromagnetic control device. This can accurately control the casting process, optimize the filling and solidification process of the alloy liquid, reduce casting defects, and improve the quality of the casting. Controlling the mold cooling rate and temperature uniformity helps to obtain a uniform and dense casting structure and improve the overall performance of the casting.

[0016] Demolding stage: After the mold is cooled to 150°C, a release agent is electrostatically sprayed (spray gun distance 15cm, pressure 0.2MPa, two sprayings with 5 minutes between each application). Demolding is performed using a combination of vibration (30Hz×0.5mm×10s) and thermal expansion and contraction (temperature drop 30°C×5s). After demolding, the surface roughness Ra is tested to be ≤0.8μm, with a yield rate ≥98%. The release agent is electrostatically sprayed at the appropriate mold temperature in two separate applications to ensure uniform coverage and form a good demolding lubricating film. The combination of vibration and thermal expansion and contraction-assisted demolding effectively reduces demolding force and minimizes damage to the casting during demolding. This results in low surface roughness and a high yield rate after demolding, improving production efficiency and product quality.

[0017] Furthermore, during the smelting stage, the alloy composition is monitored in real time via an online composition analyzer, with sampling occurring every 15 minutes. Automatic restocking occurs when composition deviations exceed ±0.5%. The raw material pretreatment process includes the use of ultrasonic cleaning equipment to remove surface impurities, with a cleaning time of 10-15 minutes. The online composition analyzer monitors the alloy composition in real time, promptly detecting composition deviations and automatically restocking, ensuring that the alloy composition consistently meets standards and improving the stability of alloy quality. Raw material pretreatment utilizes ultrasonic cleaning equipment to remove surface impurities, with cleaning time controlled within an appropriate range. This effectively removes impurities such as oil and dust from the raw material surface, preventing these impurities from entering the alloy liquid and affecting alloy quality, further improving the quality of the final casting.

[0018] Furthermore, during the casting phase, a high-speed camera (frame rate ≥1000 fps) monitors the filling process, maintaining an air entrainment rate of ≤0.1% and a filling completion rate of ≥99%. Pressure sensors are also installed in the casting system to monitor the casting pressure in real time and provide feedback to the control system, ensuring that the casting pressure remains stable within a set range. The high-speed camera monitors the filling process at a high frame rate, enabling clear observation of the flow of the molten alloy and timely detection of problems such as air entrainment. This allows the air entrainment rate to be controlled to an extremely low level, improving the filling completion rate and reducing internal defects in the casting. The installation of pressure sensors in the casting system to monitor the casting pressure in real time and provide feedback to the control system ensures stable casting pressure, ensuring smooth filling of the molten alloy and further improving casting quality and production process stability.

[0019] Furthermore, during the demolding stage, a casting identification code traceability system is established, which is associated with more than 30 production data items such as melting time and casting parameters. The data storage period is ≥5 years, and hardness testing is performed on the castings after demolding. The hardness value must be within the range specified by the product standard. A casting identification code traceability system is established, which is associated with a large amount of production data and stored for a long time. This facilitates the traceability and analysis of casting quality, helps to discover potential problems in the production process, and provides data support for process improvement. Hardness testing is performed on castings after demolding to ensure that the hardness value meets the product standard, which can effectively control product quality and ensure that product performance meets the requirements.

[0020] Furthermore, during the defective product processing phase, defective castings are classified and processed. Defect analysis reports include over 10 data points, including macromorphology, composition testing, and mechanical properties. The rework rate is kept below 5%, and scrapped castings are recycled, with the recycling process adhering to environmental standards. During this stage, detailed defect analysis of defective castings, covering macromorphology, composition testing, mechanical properties, and other data, helps pinpoint the causes of defects and provides a strong basis for improving production processes. Keeping the rework rate low can improve production efficiency and reduce costs. Recycling scrap castings in accordance with environmental standards not only meets environmental requirements, but also effectively utilizes resources and reduces waste.

[0021] Compared with the prior art, the present invention has the following beneficial effects:

[0022] 1. Significantly Improved Product Quality: During the Melting Stage, a resistance melting furnace equipped with high-precision PID temperature control provides precise temperature control to avoid alloy composition deviations. Rotary spraying and multi-layer filter screens work together to efficiently remove gases and impurities, improving alloy purity and uniformity. During the Casting Stage, a magnetorheological fluid-coated mold, combined with electromagnetic control, reduces viscosity during filling to minimize defects and increases viscosity during solidification to inhibit shrinkage cavities and porosity, thereby improving casting density and performance. During the Demolding Stage, electrostatic spraying precisely applies release agent, and multiple demolding methods work together to minimize surface damage, improve dimensional accuracy, and increase yield.

[0023] 2. Significantly Improve Production Efficiency: Melting Unit: Automated refining agent addition equipment enables precise feeding, shortening melting time and increasing alloy output per unit time. Casting Stage: Precisely controls pouring, transfer, and mold filling. Electromagnetic control precisely controls the casting process, shortening cycle times and enhancing production continuity. Demolding Unit: The equipment is easy to operate and quickly completes demolding, reducing the time required to remove castings and accelerating the production process.

[0024] 3. Effectively reduce production costs: Improved quality reduces waste: Precise melting and high-quality demolding reduce scrap, raw material waste, and re-production costs. Increased efficiency spreads costs: Increased output spreads fixed costs, while automation reduces labor costs, improving economic benefits. Convenient maintenance reduces expenses: Durable materials and self-cleaning features reduce maintenance and malfunctions, indirectly reducing costs.

[0025] 4. Enhanced equipment stability and process controllability: During the melting stage, the melting furnace's temperature sensors are calibrated, and multi-point monitoring improves stability. The rotary spray device undergoes strict leak detection and uses high-quality materials to ensure stable degassing. During the casting stage, electromagnetic control precisely controls the magnetic field, and real-time mold temperature monitoring and feedback ensure a stable and controllable process. During the demolding stage, flexible adjustment of demolding equipment parameters and a release agent spray device ensure stable performance and improve demolding reliability. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] Figure 1 This is a functional block diagram of a device for producing cast aluminum-magnesium alloy;

[0027] Figure 2 A flow chart of a process for producing cast aluminum-magnesium alloy;

[0028] Figure 3 Schematic diagram of the structure of aluminum-magnesium alloy aerospace antenna frame produced by the process of the present invention Figure 1 ;

[0029] Figure 4 Schematic diagram of the structure of aluminum-magnesium alloy aerospace antenna frame produced by the process of the present invention Figure 2 . DETAILED DESCRIPTION

[0030] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0031] See also Figure 1-4 The present invention provides a technical solution: an apparatus and process for producing cast aluminum-magnesium alloy, comprising:

[0032] 1. Equipment Preparation

[0033] (1) Melting unit

[0034] 1. Melting Furnace: A resistance-type melting furnace with a built-in PID temperature control system offers high temperature control precision, maintaining a stable temperature range of ±5°C. This ensures uniform heating of the aluminum-magnesium alloy raw materials during the melting process, effectively preventing alloy composition deviations caused by temperature fluctuations. Before each melting, a standard thermometer is used to measure temperatures at different locations within the furnace. Temperature sensor deviations are compared and adjusted to ensure accurate temperature measurement.

[0035] 2. Rotary Blowing Device: Installed at the center of the top of the melting furnace, the blowing head is made of a high-temperature resistant alloy, offering excellent heat and corrosion resistance and capable of 360-degree rotation. This device is connected to an argon gas supply system with adjustable flow and pressure. The gas flow rate can be precisely adjusted from 0 to 20 L / min, and the pressure can be adjusted from 0 to 0.5 MPa. The blowing parameters can be flexibly adjusted based on the actual conditions of the alloy liquid to ensure effective degassing. Before commissioning the equipment, check the sealing of the rotary blowing device by applying soapy water to the connection and observing for bubbles to prevent gas leakage.

[0036] 3. Refining Flux Dosing Device: Automated quantitative dosing equipment is used, utilizing a high-precision electronic scale for precise metering, achieving an accuracy of ±0.1kg. The equipment is equipped with a dedicated silo for storing special refining fluids (primarily composed of CaO, Na2CO3, and a small amount of flux), enabling the addition of refining fluids for multiple batch production runs. Before each use, the electronic scale of the refining fluid dosing device is calibrated with standard weights to ensure accurate refining fluid addition.

[0037] 4. Gas Filtration: A multi-layered filter structure is used, made of high-temperature-resistant stainless steel. The pore sizes are precisely set to 50μm, 20μm, and 5μm, respectively, from the inlet to the outlet. Installed on the exhaust duct of the melting furnace, this device effectively intercepts harmful gases and fine particles generated during the smelting process, reducing environmental pollution and improving alloy quality.

[0038] (2) Casting unit

[0039] 1. Casting mold: A casting mold used to produce small aluminum-magnesium alloy parts. The mold cavity surface is coated with a magnetorheological fluid coating with a thickness of precisely 0.5 mm. The viscosity is 100 mPa·s in the absence of a magnetic field. Under the action of a 1 T magnetic field, its viscosity can rapidly increase to 1000 mPa·s in an extremely short time (less than 0.1 second), which can effectively meet the requirements for controlling fluid viscosity at different stages of the casting process.

[0040] 2. Electromagnetic Control Device: This device includes an electromagnetic generator and a programmable logic controller (PLC). The electromagnetic generator generates a magnetic field whose intensity can be continuously and precisely adjusted within a range of 0-3 T. The PLC automatically controls the generator's output according to the different stages of the casting process using a pre-set program. For example, within the first 5 seconds of the filling phase, the PLC rapidly controls the magnetic field intensity to 0.3 T. Within the first 10 seconds of the solidification phase, it increases the intensity to 1.5 T, achieving precise control of the casting process.

[0041] (3) Demolding unit

[0042] 1. Release agent spraying device: Utilizes electrostatic spraying technology and is equipped with a release agent storage tank for storing the release agent, which is composed of a special polymer material and a surfactant. A high-voltage electrostatic spray gun is used to evenly apply the release agent to the mold surface. By precisely adjusting the spray gun's spray pressure (adjustable within a range of 0.1-0.3 MPa) and movement speed (adjustable within a range of 3-7 cm / s), the spray thickness can be precisely controlled to approximately 0.05 mm. Before each use of the release agent, measure the viscosity with a viscometer to ensure it is within the specified range. A batch management system for release agents is also established, recording information such as the manufacturer, production date, and usage time of each batch of release agent. Different batches are evaluated on a small scale before large-scale use.

[0043] 2. Demolding Equipment: A hydraulically driven demolding machine is used, with a demolding force that can be stably adjusted from 0 to 50 kN. This is paired with a vibration demolding device, whose vibration frequency can be precisely adjusted from 10 to 50 Hz, and whose amplitude can be flexibly adjusted from 0.1 to 1 mm. Furthermore, the mold is mounted on a platform that can accommodate thermal expansion and contraction. The platform temperature can be rapidly raised or lowered between room temperature and 200°C, with a temperature change rate of up to 5°C / s, providing reliable support for demolding.

[0044] 2. Process operation steps

[0045] (1) Melting stage

[0046] 1. Raw Material Pretreatment and Furnace Loading: 500kg of aluminum-magnesium alloy raw material undergoes comprehensive quality testing, using a spectrometer to accurately analyze its composition to ensure that the content of each element meets production standards. The raw material surface is also cleaned to remove oil, dirt, and impurities to prevent them from entering the melting furnace and affecting alloy quality. The cleaned raw material is added in batches to the melting furnace, preheated to 100°C, with each addition controlled at 50-100kg, and every five minutes between additions to ensure even distribution within the furnace.

[0047] 2. Heating and melting: Start the heating system of the smelting furnace and slowly heat it to 750°C at a heating rate of 10°C / min. During this process, use the stirring device in the furnace (the initial speed is set to 50r / min) for intermittent stirring, stirring for 1 minute every 10 minutes to promote rapid and uniform melting of the raw materials. The entire melting process takes about 65 minutes. During this period, the temperature in the furnace is monitored in real time by a temperature sensor, and the data is fed back to the PID temperature control system to ensure a steady temperature rise. Use an online composition analyzer to collect alloy liquid samples every 15 minutes for composition analysis. If it is detected that the content of key components such as magnesium deviates from the standard, the corresponding raw materials are added in appropriate amounts for adjustment in a timely manner.

[0048] 3. Rotary spray degassing: After the raw materials are completely melted, increase the speed of the stirring device to 150r / min to ensure that the alloy liquid is in a fully fluid state. Start the rotary spray device and spray argon into the alloy liquid at a flow rate of 10L / min and a pressure of 0.2MPa. The spraying time should be exactly 20 minutes. During this process, argon bubbles rise at a rate of about 5-10 per second, efficiently bringing hydrogen and other gases in the alloy liquid to the liquid surface. Every 5 minutes, use a gas detection instrument to sample and test the gas content in the alloy liquid. After testing, the hydrogen content in the alloy liquid can be reduced by about 80%.

[0049] 4. Refining agent addition and stirring reaction: Add 7.5kg of refining agent (accounting for 1.5% of the mass of the alloy liquid) to the alloy liquid through automated quantitative addition equipment. The addition process lasts for 2-3 minutes to ensure that the refining agent is evenly dispersed on the surface of the alloy liquid. After addition, immediately use the stirring device, increase the speed to 200r / min, and stir for 10 minutes to allow the refining agent to fully react with the remaining harmful gases to generate solid or gaseous products. During the stirring process, closely observe the changes in the color and fluidity of the alloy liquid. After the reaction, the harmful gas content can be reduced by about 90%.

[0050] 5. Gas Filtration: The gas filtration device is turned on to continuously filter the exhaust gases from the smelting furnace for 15 minutes. During the filtration process, the filter screen is checked every 3 minutes to prevent clogging that may affect the filtration effect. This ensures that any remaining tiny bubbles and solid impurities generated by the reaction are effectively trapped, with a retention efficiency exceeding 95%. The filtered gas is tested and released into the atmosphere after meeting the required standards.

[0051] (2) Casting stage

[0052] 1. Preheating and preparation of the casting system: When the smelting stage reaches the later stage, the casting system is preheated. Raise the temperature of the casting system to 200°C and maintain it for 30 minutes to ensure that the internal temperature is uniform and reduce the temperature loss when the alloy liquid is injected. At the same time, check whether the pipe connections of the casting system are tight and whether the valve switches are flexible to ensure a smooth casting process. Use a transfer bag with a heating function to transfer the alloy liquid. The heating power of the transfer bag is adjusted according to the actual transfer time and ambient temperature to ensure that the temperature of the alloy liquid does not drop by more than 10°C during the transfer process. Install a flow sensor on the transfer pipeline to monitor the flow rate of the alloy liquid in real time, and adjust it through the valve to stabilize it at 6-7kg per second.

[0053] 2. Alloy Transfer and Mold Filling: The molten alloy, which has been smelted and stabilized at a temperature of 730°C, is poured through the casting system at a flow rate of approximately 5-8 kg per second into a casting mold coated with a magnetorheological fluid. Three seconds before filling begins, the PLC of the electromagnetic control device is activated, rapidly controlling the magnetic field strength to 0.3 T within the first five seconds of the filling phase. This rapidly reduces the viscosity of the magnetorheological fluid to 30 mPa·s, allowing the alloy to smoothly fill the mold cavity within 10 seconds. During the filling process, a high-speed camera monitors the flow of the alloy in real time to ensure a turbulent and air-entrained process, achieving a filling completion rate exceeding 99%.

[0054] 3. Magnetic Field Control During Solidification: After mold filling is complete, the solidification phase begins. Within the first 10 seconds of the solidification phase, the PLC rapidly increases the magnetic field strength of the electromagnetic control device from 0.3T to 1.5T, increasing the viscosity of the magnetorheological fluid to 800mPa·s. This effectively inhibits the flow of the molten alloy and reduces defects such as shrinkage cavities and porosity. The solidification period is 30 minutes. During this time, multiple temperature sensors evenly distributed across the mold surface monitor mold temperature changes in real time and feed the data back to the control system. The mold temperature is naturally cooled to 500°C at a rate of approximately 5°C / min. Testing has shown a reduction of approximately 70% in the shrinkage and porosity defect rate of the casting. During mold preheating, temperature sensors are placed in key locations such as the mold cavity and core. Based on sensor feedback, the power distribution of the heating elements is adjusted to maintain temperature uniformity within a ±5°C range across the mold.

[0055] (3) Demolding stage

[0056] 1. Preparation before spraying the release agent: After the casting solidifies and the mold temperature drops to 150°C, debug the electrostatic spray equipment. Check the spray gun's atomization effect and ensure uniform atomization of the release agent by adjusting the gun's air pressure and liquid flow rate. Also, check the remaining release agent in the release agent storage tank to ensure an uninterrupted spraying process.

[0057] 2. Release Agent Spraying: Use an electrostatic sprayer to evenly apply the release agent to the mold surface. Maintain a precise distance of 15 cm from the mold surface, spray at a pressure of 0.2 MPa and a speed of 5 cm / s. Ensure the release agent evenly covers the mold surface, forming a lubricating film approximately 0.05 mm thick. Spraying is performed in two steps, with a five-minute interval between each application to ensure the release agent is fully adhered to the mold surface. Spray coverage should exceed 98%.

[0058] 3. Demolding operation: Start the demoulding equipment, first set the demoulding force of the demoulding machine to 20kN, and perform the demoulding operation at a suitable demoulding angle (30 degrees). At the same time as the demoulding machine is started, turn on the vibration demoulding device, set the vibration frequency to 30Hz, the amplitude to 0.5mm, and the vibration time to 10 seconds. In addition, the temperature of the thermal expansion and contraction platform is quickly reduced by 30°C within 5 seconds, and the thermal expansion and contraction difference between the mold and the casting is used to assist in demoulding. With the synergistic effect of various demoulding methods, the casting is smoothly demoulded. After testing, the surface roughness Ra value can be controlled below 0.8μm, and the product yield rate reaches 98%. The casting is immediately inspected for appearance after demoulding, and any minor defects that may exist on the surface are recorded and preliminarily processed.

[0059] 4. Post-processing and quality inspection of castings: The demolded castings are transferred to the post-processing area for surface treatment such as deburring and grinding. Use a grinding wheel machine to remove burrs on the surface of the casting, and then use a polishing machine to polish the surface of the casting to further reduce the surface roughness. After completing the surface treatment, the castings are subjected to a comprehensive quality inspection. An ultrasonic flaw detector is used to detect whether there are defects inside the castings, and a hardness tester is used to test the hardness of the castings to ensure that all indicators meet the product quality standards. The castings that pass the inspection are packaged and prepared for storage or entering the next production link; the castings that fail the inspection are classified and marked, and after analyzing the reasons, they are reworked or scrapped as appropriate. After the casting is demolded, a unique identification code is immediately marked on the surface of the casting. The identification code is read by a scanning device to quickly query detailed information such as the casting production batch, smelting time, casting parameters, etc., and statistical analysis of the casting quality data is performed to provide data support for subsequent production process improvements.

[0060] It can be seen from the above embodiments that the equipment and process of the present invention can effectively improve the quality and efficiency of aluminum-magnesium alloy casting, and solve the problems existing in traditional processes such as incomplete gas purification, difficulty in precise control of the casting process, and easy damage to the casting during demolding.

[0061] Example 1:

[0062] Equipment preparation:

[0063] Melting Unit: 800kg resistance melting furnace, temperature control accuracy ±3°C. Rotary injection device with flow rate 0-25L / min, pressure 0-0.6MPa, leakage rate ≤0.2%. Refining agent addition accuracy ±0.05kg, 300kg silo. Gas filtration device with mesh size 60-30-8μm.

[0064] Casting unit: Medium-sized component molds, magnetorheological fluid coating thickness 0.6mm. Electromagnetic control device, magnetic field strength 0-4T.

[0065] Demolding unit: Demolding agent spray thickness 0.04mm. Demolding machine demoulding force 0-60kN, vibration frequency 8-60Hz, amplitude 0.08-1.2mm, thermal expansion and contraction platform temperature change rate 6°C / s.

[0066] Process operation steps:

[0067] Melting stage: Raw materials were added in batches and the temperature was raised to 780°C at 12°C / min. Argon was blown for 25 minutes, a refining agent was added at a rate of 1.5%, and the gas was filtered for 20 minutes.

[0068] Casting stage: The casting system is preheated to 220°C. The alloy liquid temperature drops ≤8°C. The magnetic field is precisely controlled during mold filling, the magnetic field is 1.8T during the solidification stage, and the mold cooling rate is 6°C / min.

[0069] Demolding stage: spray the release agent three times, the demoulding force is 25kN, the vibration frequency is 35Hz, and the temperature drop of the thermal expansion and contraction platform is 35℃.

[0070] The experimental data are as follows: high purity, impurities reduced by 70%; excellent mechanical properties, tensile strength increased by 20%; yield strength increased by 15%; elongation increased by 10%; high-precision molding, dimensional deviation within ±0.1mm; high production efficiency, production efficiency increased by 30%.

[0071] Example 2:

[0072] Equipment preparation:

[0073] Melting Unit: 600kg melting furnace, temperature control accuracy ±4°C. Rotary injection device with flow rate 0-18L / min, pressure 0-0.45MPa, and leakage rate ≤0.3%. Refining agent addition accuracy ±0.08kg, 250kg silo. Gas filtration device with a pore size of 55-25-6μm.

[0074] Casting unit: Small component molds, magnetorheological fluid coating thickness 0.55mm. Electromagnetic control device, magnetic field strength 0-3.5T.

[0075] Demolding unit: Demolding agent spray thickness 0.045mm. Demolding machine demoulding force 0-55kN, vibration frequency 12-45Hz, amplitude 0.12-0.8mm, thermal expansion and contraction platform temperature change rate 5.5℃ / s.

[0076] Process operation steps:

[0077] Melting stage: Raw materials were added in batches, and the temperature was raised to 760°C at 11°C / min. Argon was injected for 22 minutes, a refining agent was added at a rate of 1.4%, and the gas was filtered for 17 minutes.

[0078] Casting stage: Preheat the casting system to 210°C. The alloy liquid temperature drops by ≤9°C. The magnetic field is properly controlled during the filling and solidification stages, and the mold cooling rate is 5.5°C / min.

[0079] Demolding stage: spray the release agent twice, the demoulding force is 22kN, the vibration frequency is 32Hz, and the temperature drop of the thermal expansion and contraction platform is 32℃.

[0080] The experimental data are as follows: impurities are reduced by 60%; tensile strength is increased by 15%; yield strength is increased by 10%; elongation is increased by 8%; dimensional deviation is within ±0.15mm; production efficiency is increased by 25%.

[0081] Example 3:

[0082] Equipment preparation:

[0083] Melting Unit: 550kg melting furnace, temperature control accuracy ±4.5°C. Rotary injection device with flow rate 0-16L / min, pressure 0-0.4MPa, and leakage rate ≤0.4%. Refining agent addition accuracy ±0.09kg, 230kg silo. Gas filtration device with pore size 52-22-7μm.

[0084] Casting unit: Small component molds, magnetorheological fluid coating thickness 0.48mm. Electromagnetic control device, magnetic field strength 0-3.2T.

[0085] Demolding unit: Demolding agent spray thickness 0.048mm. Demolding machine demoulding force 0-52kN, vibration frequency 15-40Hz, amplitude 0.15-0.7mm, thermal expansion and contraction platform temperature change rate 5.2℃ / s.

[0086] Process operation steps:

[0087] Melting stage: Raw materials were added in batches, and the temperature was raised to 755°C at 10.5°C / min. Argon was injected for 21 minutes, a refining agent was added at a rate of 1.3%, and the gas was filtered for 16 minutes.

[0088] Casting stage: The casting system is preheated to 205°C. The alloy liquid temperature drops by ≤9.5°C. The magnetic field is adjusted as set during the filling and solidification stages. The mold cooling rate is 5.2°C / min.

[0089] Demolding stage: spray the release agent twice, the demoulding force is 21kN, the vibration frequency is 30Hz, and the temperature of the thermal expansion and contraction platform drops by 30℃.

[0090] The experimental data are as follows: impurities are reduced by 50%; tensile strength is increased by 10%; yield strength is increased by 8%; elongation is increased by 6%; dimensional deviation is within ±0.2mm; production efficiency is increased by 20%.

[0091] Example 4:

[0092] Equipment preparation:

[0093] Melting Unit: 450kg melting furnace, temperature control accuracy ±4.8°C. Rotary injection device with a flow rate of 0-14L / min, a pressure of 0-0.35MPa, and a leakage rate of ≤0.45%. Refining agent addition accuracy of ±0.1kg, 200kg silo. Gas filtration device with a pore size of 50-20-6μm.

[0094] Casting unit: Small component molds, magnetorheological fluid coating thickness 0.45mm. Electromagnetic control device, magnetic field strength 0-3T.

[0095] Demolding unit: Demolding agent spray thickness 0.05mm. Demolding force 0-50kN, vibration frequency 18-35Hz, amplitude 0.18-0.6mm, thermal expansion and contraction platform temperature change rate 5°C / s.

[0096] Process operation steps:

[0097] Melting stage: Raw materials were added in batches and the temperature was raised to 750°C at 10°C / min. Argon was blown for 20 minutes, a refining agent was added at a rate of 1.2%, and the gas was filtered for 15 minutes.

[0098] Casting stage: Preheat the casting system to 200°C. The alloy liquid temperature drops ≤10°C. The magnetic field is conventionally controlled during the filling and solidification stages, and the mold cooling rate is 5°C / min.

[0099] Demolding stage: spray the release agent twice, the demoulding force is 20kN, the vibration frequency is 28Hz, and the temperature drop of the thermal expansion and contraction platform is 28℃.

[0100] The experimental data are as follows: impurities are reduced by 40%; tensile strength is increased by 8%; yield strength is increased by 6%; elongation is increased by 5%; dimensional deviation is within ±0.25mm; production efficiency is increased by 15%.

[0101] Embodiment 5:

[0102] Equipment preparation:

[0103] Melting Unit: 700kg melting furnace, temperature control accuracy ±3.5°C. Rotary injection device with flow rate 0-22L / min, pressure 0-0.55MPa, and leakage rate ≤0.25%. Refining agent addition accuracy ±0.06kg, 280kg silo. Gas filtration device with pore size 58-28-7μm.

[0104] Casting unit: Medium-sized component molds, magnetorheological fluid coating thickness 0.58mm. Electromagnetic control device, magnetic field strength 0-3.8T.

[0105] Demolding unit: Demolding agent spray thickness 0.042mm. Demolding machine demoulding force 0-58kN, vibration frequency 10-50Hz, amplitude 0.1-1mm, thermal expansion and contraction platform temperature change rate 5.8℃ / s.

[0106] Process operation steps:

[0107] Melting stage: Raw materials were added in batches, and the temperature was raised to 770°C at 11.5°C / min. Argon was blown for 23 minutes, a refining agent was added at a rate of 1.45%, and the gas was filtered for 18 minutes.

[0108] Casting stage: The casting system is preheated to 215°C. The alloy liquid temperature drops by ≤9°C. The magnetic field is precisely controlled during the filling and solidification stages, and the mold cooling rate is 5.8°C / min.

[0109] Demolding stage: spray the release agent three times, the demoulding force is 23kN, the vibration frequency is 33Hz, and the temperature drop of the thermal expansion and contraction platform is 33℃.

[0110] The experimental data are as follows: impurities are reduced by 65%; tensile strength is increased by 18%; yield strength is increased by 13%; elongation is increased by 9%; dimensional deviation is within ±0.12mm; production efficiency is increased by 28%.

[0111] Example 6:

[0112] Equipment preparation:

[0113] Melting Unit: 500kg melting furnace, temperature control accuracy ±4.2°C. Rotary injection device with flow rate 0-17L / min, pressure 0-0.42MPa, and leakage rate ≤0.35%. Refining agent addition accuracy ±0.07kg, 220kg silo. Gas filtration device with mesh size 53-23-6.5μm.

[0114] Casting unit: Small component molds, magnetorheological fluid coating thickness 0.47mm. Electromagnetic control device, magnetic field strength 0-3.3T.

[0115] Demolding unit: Demolding agent spray thickness 0.046mm. Demolding machine demoulding force 0-53kN, vibration frequency 16-38Hz, amplitude 0.16-0.65mm, thermal expansion and contraction platform temperature change rate 5.3℃ / s.

[0116] Process operation steps:

[0117] Melting stage: Raw materials were added in batches, and the temperature was raised to 758°C at 10.8°C / min. Argon was injected for 21.5 minutes, a refining agent was added at a rate of 1.35%, and gas filtration was performed for 16.5 minutes.

[0118] Casting stage: The casting system is preheated to 208°C. The alloy liquid temperature drops by ≤9.2°C. The magnetic field is properly controlled during the filling and solidification stages, and the mold cooling rate is 5.3°C / min.

[0119] Demolding stage: spray the release agent twice, the demoulding force is 21.5kN, the vibration frequency is 31Hz, and the temperature drop of the thermal expansion and contraction platform is 31℃.

[0120] The experimental data are as follows: impurity reduction ratio is 55%; tensile strength is increased by 12%; yield strength is increased by 9%; elongation is increased by 7%; dimensional deviation is within ±0.18mm; production efficiency is increased by 22%.

[0121] The data of the embodiment are shown in Table 1 below:

[0122]

[0123] Table 1: Example data table.

[0124] The present invention also includes an aluminum-magnesium alloy aerospace antenna frame, which is prepared by the process described in Example 1, such as Figure 3 and Figure 4 As shown, during processing, rough processing is required followed by natural aging treatment (96 hours), that is, the product is placed on an open-air table for 96 hours of aging, and the time is noted on the yellow sheet. During rough processing, the process boss (see green boss for details) is retained, and then fine processing is performed.

[0125] In summary: In the present invention, by adopting a resistance melting furnace equipped with a high-precision PID temperature control system, the melting temperature can be precisely controlled to ensure the stability of the alloy composition. A rotary blowing device that can rotate 360 degrees and a multi-layer filter gas filtration device are used to achieve the function of efficiently removing gas impurities in the alloy liquid and purifying the gas. With the help of a casting mold coated with a magnetorheological fluid coating and an electromagnetic control device, the function of accurately controlling the casting process and optimizing the quality of the casting is achieved. A demolding unit composed of an electrostatic spraying device, a hydraulic demolding machine, a vibration demolding device and a thermal expansion and contraction platform is used to achieve the function of reducing the difficulty of demolding, reducing damage to castings and improving the yield rate. The aluminum-magnesium alloy aerospace antenna frame prepared by this scheme is suitable for use in high-load environments, such as the aerospace field, to manufacture structural components of aircraft and satellites.

Claims

1. A device for producing cast aluminum-magnesium alloy, characterized by: include: Melting unit: equipped with a resistance melting furnace, including a PID temperature control system, a rotary blowing device, an automatic refining agent addition device, and a multi-layer filter screen device; Casting unit: Contains a casting mold coated with a 0.5mm magnetorheological fluid coating, and an electromagnetic control device consisting of a 10kW electromagnetic generator and a PLC controller; Demolding unit: includes electrostatic spraying device, hydraulic demoulding machine, vibration demoulding device and thermal expansion and contraction platform.

2. The equipment for producing cast aluminum-magnesium alloy according to claim 1, characterized in that: The temperature sensor of the smelting furnace must be calibrated with a standard thermometer before each use, and the deviation must be controlled within ±2°C. At least 5 temperature monitoring points are set inside the furnace body.

3. The equipment for producing cast aluminum-magnesium alloy according to claim 1, characterized in that: The rotary blowing device is tested for sealing performance by a soapy water leak detection method before being put into use, with a leakage rate of ≤0.5%. The blowing head is made of a high-temperature-resistant and corrosion-resistant nickel-based alloy.

4. The equipment for producing cast aluminum-magnesium alloy according to claim 1, characterized in that: The refining agent adding equipment is equipped with an electronic scale calibration module, the error of which is calibrated by standard weights is ≤0.1%, and an automatic cleaning device is provided.

5. The equipment for producing cast aluminum-magnesium alloy according to claim 1, characterized in that: The release agent spraying device is provided with a viscosity detection module and a batch management module. Different batches of release agents must be tested and verified to be qualified before use, and the spray gun of the spraying device can rotate 360 degrees.

6. A process for producing cast aluminum-magnesium alloy, characterized in that: The following steps are involved: Melting stage: The pretreated raw materials are added in batches to a melting furnace preheated to 100°C, and the temperature is raised to 750°C at a rate of 10°C / min while stirring; after melting, argon is sprayed for degassing, a refining agent of 1.5% by weight is added, and finally the gas is filtered for 15 minutes; Casting stage: The casting system is preheated to 200°C, and the alloy liquid is transferred using a heated transfer bag. The flow rate is controlled by a flow sensor at 6-7 kg / s. The PLC is started 3 seconds before filling. The magnetic field during the filling stage is 0.3 T, and the magnetic field during the solidification stage is 1.5 T. The mold cooling rate is 5°C / min, and the temperature uniformity is ±5°C. Demolding stage: After the mold is cooled to 150℃, the release agent is electrostatically sprayed, combined with vibration, 30Hz×0.5mm×10s; and thermal expansion and contraction, the temperature is dropped by 30℃×5s, and then demolding is carried out.

7. A process for producing a cast aluminum-magnesium alloy according to claim 6, characterized in that: During the smelting stage, the alloy composition is monitored in real time by an online composition analyzer, sampling is performed every 15 minutes, and material is automatically replenished when the composition deviation exceeds ±0.5%. The raw material pretreatment process includes using ultrasonic cleaning equipment to remove surface impurities, and the cleaning time is 10-15 minutes.

8. A process for producing a cast aluminum-magnesium alloy according to claim 6, characterized in that: During the casting stage, a high-speed camera is used to monitor the filling process, with an air entrainment rate of ≤0.1% and a filling completion rate of ≥99%. At the same time, a pressure sensor is set in the casting system to monitor the casting pressure in real time and feed it back to the control system.

9. A process for producing a cast aluminum-magnesium alloy according to claim 6, characterized in that: During the demolding stage, a casting identification code traceability system is established, which is associated with more than 30 production data such as melting time and casting parameters. The data storage period is ≥5 years, and the hardness of the casting after demolding is tested.

10. A process for producing a cast aluminum-magnesium alloy according to claim 6, characterized in that: It also includes the defective product processing stage. When defective castings are classified and processed, the defect analysis report contains more than 10 data items such as macromorphology, composition detection, mechanical properties, etc. The rework rate is controlled within 5%, and scrapped castings are recycled.

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