Horizontal continuous casting device and casting process based on high silicon aluminum alloy

Abstract

The present invention belongs to the technical field of aluminum alloy casting applications, and specifically discloses a horizontal continuous casting device based on high-silicon aluminum alloy, including a hydraulic dumping aluminum alloy melting furnace, a liquid transfer chute, an insulated casting furnace, a servo control valve, a casting chute, a horizontal insulated furnace shell, a crystallizer, a casting machine and a cutter, etc. The casting machine is used to lead out the molded rods, and the cutter is used to cut the molded rods. The beneficial effects of the horizontal continuous casting device based on high-silicon aluminum alloy of the present invention and its casting process are: 1. Its overall structural design is reasonable, and the assembly line horizontal continuous casting of A390 aluminum alloy (high-silicon hypereutectic aluminum alloy) is realized; 2. The cast molded rods are of high quality, the primary silicon particles are the smallest in size (≈27μm), and the distribution is the most uniform. The surface quality of the pulled rods is good, and only a small amount of peeling is required for deep processing.

Description

Technical Field

[0001] The invention belongs to the technical field of aluminum alloy casting application, and specifically relates to a horizontal continuous casting device based on high-silicon aluminum alloy and a casting process thereof. Background Art

[0002] A390 aluminum alloy is a high-silicon hypereutectic aluminum alloy with good wear resistance, corrosion resistance, low linear expansion coefficient, good thermal conductivity, especially good high-temperature mechanical properties and high-temperature dimensional stability. In addition, its Si content is relatively high and its density is lower than that of eutectic and hypoeutectic aluminum alloys. Therefore, it is widely used in the manufacture of engine pistons. The low density can reduce the inertia force of the reciprocating motion of the piston.

[0003] Horizontal continuous casting has the following advantages: 1. Since the metal is cooled rapidly, the crystals are dense, the structure is uniform, and the mechanical properties are good; 2. During continuous casting, there is no riser of the pouring system on the casting, so the continuous ingot does not need to be cut off during rolling, which saves metal and improves the yield; 3. The process is simplified, and molding and other processes are eliminated, thereby reducing labor intensity; the required production area is also greatly reduced; 4. Continuous casting production is easy to mechanize and automate, and continuous casting and rolling can be achieved during ingot casting, which greatly improves production efficiency.

[0004] At present, the traditional horizontal continuous casting device is only suitable for the casting of ordinary metal materials, but not for the assembly line efficient continuous casting of A390 aluminum alloy. How to design a horizontal continuous casting device for A390 aluminum alloy is currently in urgent need of research and development.

[0005] Therefore, based on the above problems, the present invention provides a horizontal continuous casting device and a casting process thereof based on high-silicon aluminum alloy. Summary of the invention

[0006] Purpose of the invention: The purpose of the present invention is to provide a horizontal continuous casting device and a casting process based on high-silicon aluminum alloy to solve the technical problems existing in the background technology.

[0007] Technical solution: The first aspect of the present invention provides a horizontal continuous casting device based on high-silicon aluminum alloy, including a hydraulic dumping aluminum alloy melting furnace, a liquid transfer chute, an insulated casting furnace, a servo control valve, a casting chute, a horizontal insulated furnace shell, a crystallizer, a casting machine and a cutting machine; the hydraulic dumping aluminum alloy melting furnace, the liquid transfer chute, the insulated casting furnace, the casting chute, and the horizontal insulated furnace shell are connected in sequence, and the aluminum alloy melt flows successively in the hydraulic dumping aluminum alloy melting furnace, the liquid transfer chute, the insulated casting furnace, the casting chute, and the horizontal insulated furnace shell, wherein the servo control valve is installed on the insulated casting furnace to control the flow / blocking of the aluminum alloy melt, and the crystallizer is installed on one end face of the horizontal insulated furnace shell, and the aluminum alloy melt flows out of the crystallizer and enters the crystallizer for forming, the casting machine is used to lead out the formed rods, and the cutting machine is used to cut the formed rods.

[0008] In the technical solution, the horizontal continuous casting device based on high-silicon aluminum alloy also includes a temperature sensor arranged on the outer wall of the casting chute, which is used to monitor and display the temperature of the aluminum alloy melt in the casting chute.

[0009] In the technical solution, the crystallizer is arranged as a circular hollow cavity structure, the interior of the crystallizer is arranged as a boss type, the boss surface is evenly provided with cooling water spray holes, the outer wall of the crystallizer is provided with a cooling water inlet pipe, a continuously cast graphite tube is arranged in one end of the crystallizer, and the continuously cast graphite tube is fixedly connected to the crystallizer through a clamping block, wherein a sealing gasket is arranged on the outer wall of the continuously cast graphite tube, and the sealing gasket is located between the clamping block and the crystallizer.

[0010] In the technical solution, the sealing gasket includes but is not limited to calcium silicate.

[0011] In the technical solution, the horizontal continuous casting device based on high-silicon aluminum alloy also includes a heat insulation layer arranged on the inner wall of the horizontal insulation furnace shell, and a box is arranged on the outer wall of the horizontal insulation furnace shell. A plurality of intrusion heaters are arranged in the box, wherein one end of the intrusion heater is located in the horizontal insulation furnace shell, which is used to insulate and heat the aluminum alloy melt in the horizontal insulation furnace shell.

[0012] In the technical solution, the horizontal insulation furnace shell is integrally formed of a refractory and anti-sticking aluminum castable made of a coal mine, the intrusion heater is an internal heating radiation tube, the outer shell is silicon carbide, the heating body is a nitrogen carbon rod, each with a power of 8.5KW; the thermal insulation layer is a lightweight insulation brick, and the outer layer of the lightweight insulation brick is provided with a high-density ceramic fiber board or a nano insulation board.

[0013] In the technical solution, the horizontal continuous casting device based on high-silicon aluminum alloy also includes a refining and degassing machine used in conjunction with the insulation casting furnace, wherein the horizontal insulation furnace shell and the aluminum alloy melt are connected to the crystallizer with a drain valve.

[0014] In the technical solution, the horizontal continuous casting device based on high-silicon aluminum alloy also includes a first circulating water cooling structure and a second circulating water cooling structure arranged on the outer walls of both ends of the casting chute, wherein the first circulating water cooling structure and the second circulating water cooling structure are located on both sides of the temperature sensor.

[0015] The second aspect of the present invention provides a casting process for a horizontal continuous casting device based on a high silicon aluminum alloy, characterized in that it includes the following steps: step 1, melting a high silicon hypereutectic aluminum alloy in a hydraulic dumping aluminum alloy melting furnace, wherein the silicon content of the high silicon hypereutectic aluminum alloy is 17% and the melting temperature is 850 degrees Celsius. Step 2, transferring the molten high silicon hypereutectic aluminum alloy liquid to a heat preservation casting furnace through a liquid transfer chute, wherein the temperature of the high silicon hypereutectic aluminum alloy liquid in the heat preservation casting furnace is 730-740 degrees Celsius, and at the same time, opening a refining and degassing machine to refine and degas the high silicon hypereutectic aluminum alloy liquid in the heat preservation casting furnace. Step 3, opening a servo control valve to lead the silicon hypereutectic aluminum alloy liquid to a horizontal heat preservation furnace shell through a casting chute, wherein a temperature meter is used to monitor the temperature of the silicon hypereutectic aluminum alloy liquid. Step 4, casting and molding the silicon hypereutectic aluminum alloy liquid through a crystallizer. Step 5, the casting molding rod is led out through a casting machine and cut off by a cutting machine.

[0016] In the technical solution, in the steps 4 and 5, when the aluminum rod formed by the silicon hypereutectic aluminum alloy liquid is stably pulled out from the crystallizer, the rod pulling rate is 75-100 mm / min.

[0017] Compared with the prior art, the beneficial effects of the horizontal continuous casting device based on high-silicon aluminum alloy and the casting process thereof of the present invention are: 1. Its overall structural design is reasonable, realizing the assembly line horizontal continuous casting of A390 aluminum alloy (high-silicon hypereutectic aluminum alloy); 2. The cast molded rods are of high quality, the primary silicon particles are the smallest in size (≈27μm), and the distribution is the most uniform. The surface quality of the drawn rods is good, and only a small amount of peeling is required for deep processing. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Figure 1 , Figure 2 1. It is a schematic diagram of the top view of the structure of the horizontal continuous casting device based on high silicon aluminum alloy of the present invention;

[0019] Figure 3 The forming rods of the horizontal continuous casting device based on high silicon aluminum alloy of the present invention have a rod drawing rate of 75 mm / min, 100 mm / min, and 130 mm / min;

[0020] Figure 4-Figure 7 This is a schematic diagram of the analysis results when the rod pulling rate is 75 mm / min;

[0021] Figure 8-Figure 11This is a schematic diagram of the analysis results when the rod pulling rate is 100 mm / min;

[0022] Figure 12-Figure 15 This is a schematic diagram of the analysis results when the rod pulling rate is 130 mm / min;

[0023] Among them, the serial numbers in the figure are as follows: 100-hydraulic dumping aluminum alloy melting furnace, 200-liquid transfer chute, 300-insulated casting furnace, 400-refining degasser, 500-servo control valve, 600-casting chute, 601-temperature sensor, 602-first circulation water cooling structure, 603-second circulation water cooling structure, 700-horizontal insulation furnace shell, 701-thermal insulation layer, 702-box, 703-intrusion heater, 800-crystallizer, 801-cooling water spray hole, 802-cooling water inlet pipe, 803-continuous casting graphite tube, 804-sealing gasket, 805-pressure block, 900-casting machine, 1000-cutting machine. DETAILED DESCRIPTION

[0024] The present invention is further explained below in conjunction with the accompanying drawings and specific embodiments. Embodiment 1

[0025] like Figure 1 and Figure 2 The horizontal continuous casting device based on high silicon aluminum alloy shown includes a hydraulic dumping aluminum alloy melting furnace 100, a liquid transfer chute 200, a heat preservation casting furnace 300, a servo control valve 500, a casting chute 600, a horizontal heat preservation furnace shell 700, a crystallizer 800, a casting machine 900 and a cutting machine 1000;

[0026] The hydraulic dumping aluminum alloy melting furnace 100, the liquid transfer chute 200, the insulation casting furnace 300, the casting chute 600, and the horizontal insulation furnace shell 700 are connected in sequence, and the aluminum alloy melt flows successively in the hydraulic dumping aluminum alloy melting furnace 100, the liquid transfer chute 200, the insulation casting furnace 300, the casting chute 600, and the horizontal insulation furnace shell 700. Among them, the servo control valve 500 is installed on the insulation casting furnace 300 to control the flow / blocking of the aluminum alloy melt. The crystallizer 800 is installed on one end face of the horizontal insulation furnace shell 700. The aluminum alloy melt flows out of the crystallizer 800 and enters the crystallizer 800 for molding. The casting machine 900 is used to lead out the molded rods, and the cutting machine 1000 is used to cut the molded rods.

[0027] The horizontal continuous casting device based on high-silicon aluminum alloy of the present structure preferably also includes a temperature detector 601 arranged on the outer wall of the casting chute 600, which is used to monitor and display the temperature of the aluminum alloy melt in the casting chute 600. Embodiment 2

[0028] On the basis of Example 1, a horizontal continuous casting device based on high-silicon aluminum alloy is preferably configured, wherein the crystallizer 800 is configured as a circular hollow cavity structure, the interior of the crystallizer 800 is configured as a boss type, the boss surface is evenly provided with cooling water spray holes 801, the outer wall of the crystallizer 800 is provided with a cooling water inlet pipe 802, and a continuously cast graphite tube 803 is provided at one end of the crystallizer 800, and the continuously cast graphite tube 803 is fixedly connected to the crystallizer 800 through a clamping block 805, wherein a sealing gasket 804 is provided on the outer wall of the continuously cast graphite tube 803, and the sealing gasket 804 is located between the clamping block 805 and the crystallizer 800.

[0029] In the horizontal continuous casting device based on high silicon aluminum alloy of the present structure, preferably, the sealing gasket 804 includes but is not limited to calcium silicate. Embodiment 3

[0030] On the basis of Example 2, the horizontal continuous casting device based on high-silicon aluminum alloy also includes a heat insulation layer 701 arranged on the inner wall of the horizontal insulation furnace shell 700, and the outer wall of the horizontal insulation furnace shell 700 is provided with a box body 702, and a plurality of intrusion heaters 703 are arranged in the box body 702, wherein one end of the intrusion heater 703 is located in the horizontal insulation furnace shell 700, and is used to insulate and heat the aluminum alloy melt in the horizontal insulation furnace shell 700.

[0031] The horizontal continuous casting device based on high-silicon aluminum alloy of the present structure is preferred, and the horizontal insulation furnace shell 700 is integrally formed of the refractory and anti-sticking aluminum castable material of the coal mine, and the intrusion heater 703 is an internal heating radiation tube, the outer shell is silicon carbide, and the heating body is nitrogen carbon rods, the number is 6, each with 8.5KW; the heat insulation layer 701 is a lightweight insulation brick, and the outer layer of the lightweight insulation brick is provided with a high-density ceramic fiber board or a nano insulation board. Embodiment 4

[0032] On the basis of the third embodiment, the horizontal continuous casting device based on high silicon aluminum alloy further includes a refining degasser 400 used in conjunction with the heat preservation casting furnace 300, wherein the horizontal heat preservation furnace shell 700 and the aluminum alloy melt are connected by the crystallizer 800 and are provided with a tapping valve ( Figure 2 Not marked in the figure), used to control the flow or blocking of the aluminum alloy melt in the horizontal insulation furnace shell 700, and the first circulating water cooling structure 602 and the second circulating water cooling structure 603 (used to cool down the temperature in the casting chute 600, the casting temperature of the forming rod is 730-740 degrees Celsius) arranged on the outer walls of both ends of the casting chute 600, wherein the first circulating water cooling structure 602 and the second circulating water cooling structure 603 are located on both sides of the temperature detector 601.

[0033] The casting process of the horizontal continuous casting device based on high silicon aluminum alloy of the present invention is characterized by comprising the following steps:

[0034] Step 1: Melt a high-silicon hypereutectic aluminum alloy in a hydraulic dumping aluminum alloy melting furnace 100, wherein the high-silicon hypereutectic aluminum alloy has a silicon content of 17% and a melting temperature of 850 degrees Celsius.

[0035] Step 2: Transfer the molten high-silicon hypereutectic aluminum alloy liquid to the insulation casting furnace 300 through the liquid transfer chute 200. The temperature of the high-silicon hypereutectic aluminum alloy liquid in the insulation casting furnace 300 is 730-740 degrees Celsius. At the same time, start the refining and degassing machine 400 to refine and degas the high-silicon hypereutectic aluminum alloy liquid in the insulation casting furnace 300.

[0036] Step 3: Open the servo control valve 500 to guide the silicon hypereutectic aluminum alloy liquid to the horizontal insulation furnace shell 700 through the casting chute 600, wherein the temperature of the silicon hypereutectic aluminum alloy liquid is monitored by the temperature detector 601.

[0037] Step 4: Casting the silicon hypereutectic aluminum alloy liquid into shape through the crystallizer 800.

[0038] Step 5: The cast rod is led out through the casting machine 900 and cut by the cutting machine 1000.

[0039] In addition, in the steps 4 and 5, when the aluminum rod formed by the silicon hypereutectic aluminum alloy liquid is stably pulled out from the crystallizer, the rod pulling rate is 75-100 mm / min.

[0040] Among them, after testing, see Figure 3 When the rod pulling rate in steps 4 and 5 is 75 mm / min, the quality of the cast molded rods is excellent. At a rod pulling rate of 75 mm / min, the size of the primary silicon particles is the smallest (≈27 μm) and the distribution is the most uniform. At rod pulling rates of 100 mm / min and 130 mm / min, the size of the primary silicon particles is the coarsest (≈38 μm) and the distribution is uneven, among which the distribution is the most uneven at a rod pulling rate of 130 mm / min.

[0041] Figure 4-Figure 7 This is a schematic diagram of the analysis results of the rod pulling rate of 75mm / min, from the microphotograph and the light

[0042] Observation of the polished cross-section shows that: 1. There is obvious macro-segregation, with more silicon in the upper part and less silicon in the lower part, and there are large silicon-free α phase areas (at a rod pulling rate of 75mm / min, α dendrites are less developed than at 130mm / min, and the size of primary silicon particles is also smaller); 2. The distribution uniformity of silicon particles in the upper half is better than that in the lower half; 3. The distribution of silicon particles at the edge of the upper half and the 1 / 2 radius area is roughly the same; 4. The distribution uniformity of silicon particles at the edge of the lower half is slightly better than that at the 1 / 2 radius; 5. The distribution of silicon particles in the center is roughly the same as that in other areas of the upper half, and there are small areas with fewer silicon particles in some areas.

[0043] Figure 8-Figure 11 This is a schematic diagram of the analysis results when the rod pulling rate is 100 mm / min, from the microphotograph and the light

[0044] Observing the polished section from below, we can see that: 1. There is a slight macro-segregation, with slightly more silicon in the upper part than in the lower part; 2. The distribution uniformity of silicon particles in the upper part is better than that in the lower part; 3. The distribution of silicon particles at the edge of the upper part and the 1 / 2 radius area is roughly the same; 4. The distribution uniformity of silicon particles at the edge of the lower half is slightly better than that at the 1 / 2 radius; 5. The distribution of silicon particles in the center part is roughly the same as that in other areas of the upper half, and there are small areas with fewer silicon particles in some parts.

[0045] Figure 12-Figure 15 The schematic diagram of the analysis results of the rod pulling rate of 130mm / min is shown in the microphotograph and the light.

[0046] Observation of the polished cross section under light shows that: 1. There is macro segregation, with more silicon in the upper part than in the lower part; 2. The distribution uniformity of silicon particles in the upper part is better than that in the lower part; 3. The distribution of silicon particles in the edge area of ​​the upper part is slightly better than that at the 1 / 2 radius;

[0047] 4. The distribution uniformity of silicon particles at the edge of the lower half is slightly better than that at the 1 / 2 radius; 5. The distribution of silicon particles in the center is more uniform, with a higher density, and there are small areas of low silicon particle density in some areas.

[0048] The above description is only a preferred embodiment of the present invention. It should be pointed out that a person skilled in the art can make several improvements without departing from the principle of the present invention. These improvements should also be regarded as within the scope of protection of the present invention.

Claims

1. A horizontal continuous casting device based on high silicon aluminum alloy, characterized in that: The invention comprises a hydraulic dumping aluminum alloy melting furnace (100), a liquid transfer chute (200), a heat-insulating casting furnace (300), a servo control valve (500), a casting chute (600), a horizontal heat-insulating furnace shell (700), a crystallizer (800), a casting machine (900) and a cutting machine (1000); the hydraulic dumping aluminum alloy melting furnace (100), the liquid transfer chute (200), the heat-insulating casting furnace (300), the casting chute (600) and the horizontal heat-insulating furnace shell (700) are connected in sequence, and the aluminum alloy melt is poured into the hydraulic dumping aluminum alloy melting furnace (100), The liquid transfer chute (200), the insulation casting furnace (300), the casting chute (600), and the horizontal insulation furnace shell (700) flow in sequence, wherein the servo control valve (500) is installed on the insulation casting furnace (300) and is used to control the flow / blocking of the aluminum alloy melt, the crystallizer (800) is installed on an end surface of the horizontal insulation furnace shell (700), the aluminum alloy melt flows out of the crystallizer (800) and enters the crystallizer (800) for molding, the casting machine (900) is used to lead out the molded rods, and the cutting machine (1000) is used to cut the molded rods; The crystallizer (800) is configured as a circular hollow cavity structure, the interior of the crystallizer (800) is configured as a boss shape, the boss shape surface is evenly provided with cooling water spray holes (801), the outer wall of the crystallizer (800) is provided with a cooling water inlet pipe (802), a continuously cast graphite tube (803) is provided inside one end of the crystallizer (800), the continuously cast graphite tube (803) is fixedly connected to the crystallizer (800) via a clamping block (805), wherein a sealing gasket (804) is provided on the outer wall of the continuously cast graphite tube (803), and the sealing gasket (804) is located between the clamping block (805) and the crystallizer (800); It also includes a heat insulation layer (701) arranged on the inner wall of the horizontal heat insulation furnace shell (700), a box (702) arranged on the outer wall of the horizontal heat insulation furnace shell (700), and a plurality of intrusion heaters (703) arranged in the box (702), wherein one end of the intrusion heater (703) is located in the horizontal heat insulation furnace shell (700) and is used to heat and insulate the aluminum alloy melt in the horizontal heat insulation furnace shell (700); It also includes a refining and degassing machine (400) used in conjunction with the heat-insulating casting furnace (300), wherein a tapping valve is provided at the connection between the horizontal heat-insulating furnace shell (700) and the aluminum alloy melt and the crystallizer (800).

2. The horizontal continuous casting device based on high silicon aluminum alloy according to claim 1 is characterized in that: The horizontal continuous casting device based on high-silicon aluminum alloy also includes a temperature detector (601) arranged on the outer wall of the casting chute (600) for monitoring and displaying the temperature of the aluminum alloy melt in the casting chute (600).

3. The horizontal continuous casting device based on high silicon aluminum alloy according to claim 1, characterized in that: The sealing gasket (804) includes but is not limited to calcium silicate.

4. The horizontal continuous casting device based on high silicon aluminum alloy according to claim 1, characterized in that: The horizontal insulation furnace shell (700) is integrally formed of a refractory and anti-sticking aluminum castable made of a coal mine. The intrusion heater (703) is an internal heating radiation tube, the outer shell of which is made of silicon carbide, and the heating body is a nitrogen carbon rod, each of which has a power of 8.5 kW. The heat insulation layer (701) is a lightweight insulation brick, and the outer layer of the lightweight insulation brick is provided with a high-density ceramic fiber board or a nano insulation board.

5. The horizontal continuous casting device based on high silicon aluminum alloy according to claim 1, characterized in that: The horizontal continuous casting device based on high-silicon aluminum alloy also includes a first circulating water cooling structure (602) and a second circulating water cooling structure (603) arranged on the outer walls of both ends of the casting chute (600), wherein the first circulating water cooling structure (602) and the second circulating water cooling structure (603) are located on both sides of the temperature detector (601).

6. The casting process of the horizontal continuous casting device based on high silicon aluminum alloy according to claim 1, characterized in that: The following steps are included: Step 1, melting a high-silicon hypereutectic aluminum alloy in a hydraulic dumping aluminum alloy melting furnace (100), wherein the high-silicon hypereutectic aluminum alloy has a silicon content of 17% and a melting temperature of 850 degrees Celsius; Step 2: transferring the molten high-silicon hypereutectic aluminum alloy liquid to the insulation casting furnace (300) through the liquid transfer chute (200); the temperature of the high-silicon hypereutectic aluminum alloy liquid in the insulation casting furnace (300) is 730-740 degrees Celsius; and at the same time, starting the refining and degassing machine (400) to refine and degas the high-silicon hypereutectic aluminum alloy liquid in the insulation casting furnace (300); Step 3, opening the servo control valve (500) to guide the silicon hypereutectic aluminum alloy liquid to the horizontal insulation furnace shell (700) through the casting chute (600), wherein the temperature of the silicon hypereutectic aluminum alloy liquid is monitored by a temperature detector (601); Step 4, casting the silicon hypereutectic aluminum alloy liquid into a crystallizer (800); Step 5: The cast rod is led out through the casting machine (900) and cut by the cutting machine (1000).

7. The casting process of the horizontal continuous casting device based on high silicon aluminum alloy according to claim 6, characterized in that: In the steps 4 and 5, when the aluminum rod formed by the silicon hypereutectic aluminum alloy liquid is stably pulled out from the crystallizer, the rod pulling rate is 75-100 mm / min.

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