Detecting and classifying hard and soft inclusions in liquid metal
a liquid metal and inclusion technology, applied in the field of detection and classification of hard and soft inclusions in liquid metal, can solve the problems of pinholes, molten salt inclusion carryover, and inability to stabilize aluminum chlorid
Inactive Publication Date: 2001-06-28
ARCONIC INC
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Problems solved by technology
The aluminum chloride is not stable and tends to react to form magnesium chloride.
Such granular salts in the furnace cause some carryover of molten salt inclusions.
Inclusions cause problems which depend on the type of product and the gauge of the product.
In beverage can or food can sheet, for example, pinholes are serious concerns.
Inclusions cause breakage of wire during drawing operations.
Inclusions cause surface imperfections such as streaking in bright products such as reflector sheet or automobile trim.
Inclusions also cause surface defects during extrusion processes.
Inclusions also serve as nucleating sites for the formation of gas bubbles during solidification and thereby affect the fatigue life of certain products.
It is difficult to know whether hard inclusions or soft inclusions cause particular problems because of an inability to distinguish between different inclusions.
Inclusions in the metal are analyzed by destructive methods of analysis.
However, the metallographic analysis is only semi-quantitative and does not provide results in real time.
However, ultrasonic testing is performed only on the metal after it is solidified into a solid part.
Much smaller inclusions cause problems in certain products.
It is difficult to kno
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[0082] A LiMCA II Particle Detector and Classifier (LiMCA PDC) was assembled, and the LiMCA PDC system hardware and software was ported to a Toshiba laptop computer. On-line field tests were performed. As a result of these field tests, several suggestions were made for modifications, enhancements, and simplifications to the user interface software and were subsequently implemented. A macro for Excel spreadsheets also was specified and created that simplified the reading and plotting of output data files from both the LiMCA and LiMCA PDC. The macro enabled the user to select parameters specifying particle size histogram ranges and to select the plotting of counts-per-Kilogram and percentages of hard and soft particles on the same graphs automatically. The field data were used to verify the accuracy of the detection and classification probabilities for the two pulse types.
[0083] A potential ground isolation problem was observed between one of the MMP LiMCAs and the analog-digital conv...
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Apparatus and method are disclosed for providing a classification of inclusions in molten metal. The apparatus and method include the steps of and means for obtaining an analog signal stream from a data collection apparatus, passing the analog signal stream through an analog to digital converter to convert the analog signal stream to a digital signal stream, and partitioning the digital signal stream into a discrete time frame of 5 milliseconds. The digital signal stream is vector normalized to provide a normalized signal stream having a largest amplitude magnitude of 1. The normalized signal stream is compared to a control of a prototype shape for determining a classification for the digital signal stream over the discrete time frame by decision logic to determine hard inclusions versus soft inclusions in the liquid metal. In one aspect, the normalized signal stream is passed through a decision module having at least one threshold unit and at least one digital logic table to make a decision of a soft, deformable inclusion or a hard inclusion. In one embodiment, the classification and size of the inclusions are counted in an histogram of classification and a histogram of size. The classification and size of the inclusions are viewed in a graphical user interface.
Description
[0001] 1. Technical Field[0002] This invention relates to a method and apparatus for sensing inclusions in molten metal.[0003] 2. Background[0004] Inclusions in molten or liquid metal are impurities found in the liquid metal. The presence of inclusions can affect the quality of ingots cast from that liquid metal. The quality of the ingot affects the quality of the subsequent sheet and plate products fabricated from that ingot.[0005] High concentrations of inclusions in molten or liquid metal, e.g., such as inclusions in molten aluminum typically at sizes of 15 to 120 microns and in amounts over about three kilocounts per kilogram, adversely affect metal quality.INTRODUCTION TO THE INVENTION[0006] The impurities forming the inclusions in the liquid metal, in contrast to elemental impurities, are particles of separate phases suspended in the metal.[0007] The inclusions in the liquid metal can be classified into one of two types of inclusions. The two types are hard and soft inclusions...
Claims
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Login to View More IPC IPC(8): G01N15/12G01N33/20
CPCG01N15/12G01N33/206G01N33/205
InventorMANZINI, RICHARD A.DE YOUNG, DAVID H.
OwnerARCONIC INC