Gas protection optimization method in magnesium alloy smelting process

Abstract

The invention discloses a gas protection optimization method in a magnesium alloy smelting process, which can realize the capability of monitoring and dynamically adjusting gas components in the smelting process in real time. The proportion of the inert gas to the active gas can be accurately regulated and controlled according to the surface characteristics and solubility changes of the melt in different smelting stages (such as heating, feeding, stirring, active gas introduction and the like), and the optimal gas protection effect is ensured. Specifically, by means of the method, the risk of impurity introduction can be remarkably reduced, the melt fluidity is improved, and finally the quality and performance of the alloy are improved. In addition, the inert gas environment is kept in the whole process until the alloy is completely solidified, residual protective gas is safely discharged, and the safety and environmental protection performance of the smelting process are further guaranteed.

Description

Technical Field

[0001] The invention belongs to the technical field of magnesium alloy processing, and in particular relates to a gas protection optimization method in a magnesium alloy smelting process. Background Art

[0002] In the magnesium alloy smelting process, gas protection is crucial to prevent oxidation and improve the quality of the alloy. The existing technology usually uses inert gases such as argon or helium to cover the surface of the melt to form a protective layer to prevent oxygen in the air from reacting with the magnesium alloy at high temperature. However, there are some limitations in the existing gas protection methods, especially in monitoring and adjusting the gas composition during the smelting process. For example, in traditional smelting operations, the supply of inert gas is often controlled at a fixed flow rate based on preset parameters, and fails to be dynamically adjusted according to the actual state of the melt. This may lead to poor gas protection effects, especially in key stages such as feeding and stirring, which can easily introduce impurities or cause alloy performance to deteriorate.

[0003] The main problem of the existing technology is the lack of effective monitoring and real-time adjustment capabilities of the gas composition during the smelting process. This static gas management method cannot adapt to changes in the melt state, especially in the links of alloy raw material input, stirring and active gas introduction. Inappropriate gas composition may cause the surface characteristics of the melt to deteriorate, affecting the quality of the final alloy. Summary of the invention

[0004] The object of the present invention is to provide a method for optimizing gas protection in a magnesium alloy smelting process to solve the problems raised in the above background technology.

[0005] To achieve the above object, the present invention adopts the following technical solution: a method for optimizing gas protection in a magnesium alloy smelting process, comprising the following steps:

[0006] Prepare the smelting environment, ensure that the furnace is clean and free of impurities, and then inject basic inert gas to form a preliminary protective atmosphere;

[0007] In the initial protective atmosphere, the temperature is gradually raised to the preset temperature. During this period, the gas pressure is continuously monitored, and inert gas is added in time to maintain a stable pressure level. Based on the temperature and pressure conditions reached, the alloy raw material feeding mechanism is started, and the inert gas flow rate is dynamically adjusted while feeding;

[0008] As the alloy raw materials are completely melted, the changes in the surface characteristics of the melt are monitored, and the surface state of the melt is evaluated through an optical sensing device, and the inert gas composition ratio is fine-tuned accordingly;

[0009] According to the surface state evaluation results, the melt stirring operation is carried out, while keeping the inert gas flow direction coordinated with the airflow generated by the stirring. During the stirring process, active gas is introduced.

[0010] Continue the smelting process according to the set active gas concentration, track the gas dissolution in the melt in real time, and adjust the active gas input rate according to the solubility change;

[0011] When approaching the scheduled end time of smelting, the temperature is gradually lowered and the supply of inert gas is reduced simultaneously. After the temperature is lowered, the cooling procedure is executed and the inert gas environment is maintained throughout the process until the alloy is completely solidified. Finally, the remaining protective gas is safely discharged to complete the entire smelting process.

[0012] Preferably, the forming of a preliminary protective atmosphere comprises:

[0013] Determine the cleanliness index of the furnace interior, obtain the thickness of the residue on the furnace inner wall through the detection device, and if the thickness is greater than the set threshold, start the automatic cleaning program until the thickness meets the standard;

[0014] Based on the cleanliness index obtained, calculate the basic inert gas injection amount to ensure that the injection amount is suitable for the current cleaning status;

[0015] Start the gas injection system to evenly distribute the calculated basic inert gas volume in the furnace space, monitor the pressure in the furnace, and record the initial pressure value;

[0016] According to the initial pressure value, the gas flow controller is adjusted to keep the pressure in the furnace stable within the target range.

[0017] Preferably, the step of gradually heating up the temperature to a preset temperature in the preliminary protective atmosphere, continuously monitoring the gas pressure, and replenishing the inert gas in a timely manner to maintain a stable pressure level comprises:

[0018] Set the preheating rate, calculate the required heating time based on the initial furnace temperature and target temperature, start the pressure monitoring system, and record the current gas pressure; if the pressure is lower than the preset minimum value, the inert gas replenishment mechanism is triggered;

[0019] Based on the recorded pressure value, adjust the inert gas injection rate to ensure that the gas pressure quickly returns to a safe range;

[0020] As gas injection is adjusted, the temperature changes in the furnace are monitored in real time, and the heating power is fine-tuned according to the changes to ensure that the temperature rise meets the predetermined rate.

[0021] Preferably, based on the temperature and pressure conditions reached, the alloy raw material feeding mechanism is started, and the inert gas flow rate is dynamically adjusted while feeding, including:

[0022] Set the alloy raw material feeding rate, calculate the feeding cycle according to the current furnace temperature and target temperature, and ensure that the feeding process is coordinated with the temperature rise;

[0023] Start the inert gas flow monitoring system and record the initial flow rate; if the flow rate is detected to be lower than the preset minimum value, the flow adjustment mechanism is triggered;

[0024] Based on the recorded flow rate and combined with the feeding rate, the inert gas flow rate is dynamically adjusted to ensure that the gas flow rate is adjusted in time with the feeding rate changes;

[0025] As the flow rate is adjusted, the pressure in the furnace is monitored in real time, and the amount of gas replenishment is fine-tuned according to pressure changes.

[0026] Preferably, as the alloy raw material is completely melted, the changes in the surface characteristics of the melt are monitored, the surface state of the melt is evaluated by an optical sensing device, and the ratio of the inert gas components is finely adjusted accordingly, including:

[0027] Start the optical sensing device to continuously monitor the changes in the surface characteristics of the melt and record the initial reflectivity; when the raw material is completely melted, obtain the real-time reflectivity;

[0028] Based on the recorded reflectivity changes, the melt surface condition indicators are evaluated to ensure accurate reflection of the melt surface characteristics;

[0029] According to the obtained state index, the inert gas composition adjustment amount is calculated to ensure that the inert gas composition matches the melt surface state;

[0030] After the composition adjustment is performed, the new reflectivity of the melt surface is monitored and the reflectivity difference before and after the adjustment is compared; if it exceeds the preset range, the inert gas composition ratio is further fine-tuned.

[0031] Preferably, the melt stirring operation is performed based on the surface state evaluation result, while keeping the flow direction of the inert gas coordinated with the airflow generated by the stirring, including:

[0032] According to the melt surface state index obtained, the stirring rate is determined to ensure that the stirring rate is adapted to the current melt surface characteristics;

[0033] Start the stirring device, operate it at the calculated rate, and record the initial inert gas flow direction; at the same time, monitor the direction of the gas flow generated by the stirring;

[0034] Based on the recorded airflow direction, adjust the position of the inert gas injection point so that the gas flow direction is coordinated with the airflow direction generated by stirring, ensuring that the gas flow direction is synchronized with the stirring airflow;

[0035] As adjustments are made, the changes in the reflectivity of the melt surface and the direction of the gas flow are continuously monitored. If fluctuations are found to be outside the set range, the gas injection point position and stirring rate are fine-tuned.

[0036] Preferably, the active gas is introduced during the stirring process, comprising:

[0037] Determine the timing of introducing active gas based on the melt surface reflectivity and gas flow direction during stirring operation; start the active gas injection system when the reflectivity is stable and the gas flow direction is as expected;

[0038] Set the maximum allowable ratio of active gas, calculate the maximum amount of active gas introduced based on the current total gas volume, and ensure that the active gas content does not exceed a certain percentage;

[0039] After execution, active gas is gradually introduced while monitoring melt fluidity indicators to evaluate the fluidity improvement effect;

[0040] As the active gas is introduced, the changes in melt temperature and pressure are monitored in real time. If abnormal fluctuations are found to exceed the safe range, the rate of active gas introduction is slowed down until it returns to the normal range.

[0041] Preferably, adjusting the reactive gas input rate according to the solubility change comprises:

[0042] According to the set active gas concentration, the real-time gas solubility monitoring system is started to record the initial solubility; as the smelting process continues, the gas dissolution in the melt is continuously tracked;

[0043] Based on the recorded initial solubility, calculate the current solubility change to ensure accurate capture of the solubility change trend;

[0044] According to the obtained solubility change, the input rate of the active gas is adjusted to ensure that the input rate is dynamically adjusted with the solubility change;

[0045] After the rate adjustment is performed, the changes in melt temperature and pressure are monitored, and the total content of active gases is evaluated; if it is found that the temperature or pressure fluctuations exceed the safe range, or the total content of active gases exceeds the maximum allowable ratio, the input rate is fine-tuned until it returns to the normal range.

[0046] Preferably, when approaching the predetermined smelting end time, gradually lowering the temperature and simultaneously reducing the inert gas supply amount comprises:

[0047] Set the scheduled smelting end time, and calculate the remaining time based on the current time; when the remaining time enters the preset cooling preparation stage, start the temperature and gas supply adjustment program;

[0048] Based on the determined time point for entering the cooling preparation phase, gradually reduce the furnace heating power to ensure a steady temperature drop;

[0049] During the execution, the inert gas supply is reduced synchronously to ensure that the inert gas supply matches the temperature reduction process and maintain a stable environment in the melt;

[0050] As the gas supply is adjusted, the changes in pressure and temperature inside the melt are continuously monitored; if it is found that the pressure or temperature fluctuations exceed the safe range, the heating power and inert gas supply are fine-tuned until they return to the normal range.

[0051] Preferably, the cooling process is performed to maintain an inert gas environment throughout the process until the alloy is completely solidified, including:

[0052] According to the furnace temperature after warming, set the initial conditions of the cooling program; start the cooling system and record the initial inert gas environment parameters, including pressure and gas composition ratio;

[0053] Based on the recorded initial environmental parameters, the cooling rate is gradually increased. As the cooling rate is adjusted, the solidification progress of the alloy is monitored in real time to ensure accurate judgment of the alloy solidification state.

[0054] Perform solidification monitoring. When it is detected that the alloy is fully solidified, that is, the solidification progress reaches 100%, start the safe discharge procedure of the remaining protective gas; then, monitor the pressure changes inside the furnace; if it exceeds the safe discharge range, adjust the discharge rate until it stabilizes within the safe range.

[0055] Technical effects and advantages of the present invention: Compared with the prior art, the gas protection optimization method in the magnesium alloy smelting process proposed by the present invention has the following advantages:

[0056] This method is able to achieve real-time monitoring and dynamic adjustment of the gas composition during the smelting process. Through this method, the ratio of inert gas and active gas can be accurately controlled according to the surface characteristics and solubility changes of the melt at different stages of smelting (such as heating, feeding, stirring, introduction of active gas, etc.) to ensure the best gas protection effect. Specifically, this method can significantly reduce the risk of impurity introduction, improve melt fluidity, and ultimately improve the quality and performance of the alloy. In addition, the inert gas environment is maintained throughout the process until the alloy is completely solidified, and the remaining protective gas is safely discharged, further ensuring the safety and environmental protection of the smelting process. BRIEF DESCRIPTION OF THE DRAWINGS

[0057] Figure 1 The present invention is a flow chart of a method for optimizing gas protection in a magnesium alloy smelting process. DETAILED DESCRIPTION

[0058] The following will be combined with the accompanying drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, rather than all the embodiments. The specific embodiments described herein are only used to explain the present invention and are not used to limit the present invention. Based on the embodiments in the present invention, all other embodiments obtained by ordinary technicians in this field without making creative work are within the scope of protection of the present invention.

[0059] The present invention provides Figure 1 A gas protection optimization method in a magnesium alloy smelting process is shown, comprising the following steps:

[0060] Step 1: Prepare the smelting environment, ensure that the furnace is clean and free of impurities, then inject basic inert gas to form a preliminary protective atmosphere; further including:

[0061] Determine the cleanliness index X inside the furnace, obtain the thickness T of the residue on the inner wall of the furnace through the detection device, and if T is greater than the set threshold T0, start the automatic cleaning program until T≤T0; obtain the thickness T of the residue on the inner wall of the furnace through the detection device, and set the threshold T0 to ensure that subsequent operations are performed only when the furnace reaches the predetermined cleanliness standard. This process can significantly reduce the risk of impurities introduced and avoid the impact of impurities on the quality of magnesium alloys during the smelting process. Starting the automatic cleaning program until T≤T0 can ensure that the furnace is always in the best clean state, thereby improving the purity and performance of the final product.

[0062] Based on the obtained cleanliness index X, the basic inert gas injection amount V1 is calculated; the formula is V1 = α*(X+β), where α and β are preset parameters to ensure that the injection amount is adapted to the current clean state; this method ensures that the injection amount of inert gas matches the actual clean state of the furnace, and neither wastes resources due to excessive injection nor leads to poor protection effect due to insufficient injection. The preset parameters α and β can be flexibly adjusted according to specific smelting conditions to meet different smelting needs.

[0063] After execution, the gas injection system is started to evenly distribute the calculated basic inert gas volume V1 in the furnace space, while monitoring the pressure P1 in the furnace and recording the initial pressure value P1; this step not only ensures the uniform distribution of the inert gas in the entire furnace, forming a preliminary protective atmosphere, but also provides benchmark data for subsequent pressure control. The evenly distributed inert gas layer can effectively isolate the outside air and prevent the occurrence of oxidation reactions.

[0064] According to the initial pressure value P1, the gas flow controller is adjusted to keep the pressure in the furnace stable within the target range [Pmin, Pmax]; the formula is expressed as the adjusted flow F1 = γ*(P-P1), where γ is the sensitivity coefficient, which is used to fine-tune the flow to the ideal state to ensure the continued effectiveness of the protective atmosphere. This step ensures the stability of the pressure in the furnace and prevents gas protection failure or changes in melt characteristics due to pressure fluctuations. A stable gas pressure environment helps maintain optimal smelting conditions and further guarantees the quality and smelting efficiency of the alloy.

[0065] Step 2: In the protective atmosphere formed in step 1, gradually raise the temperature to a preset temperature, continuously monitor the gas pressure during the process, and replenish inert gas in time to maintain a stable pressure level; further comprising:

[0066] Set the preheating rate R1, and calculate the required heating time t1 according to the initial furnace temperature T1 and the target temperature Tf; the formula is t1 = (Tf-T1) / R1, to ensure a smooth heating process; this preheating rate setting based on the initial furnace temperature T1 and the target temperature Tf can effectively avoid the problem of excessive temperature gradient caused by rapid heating, and reduce the impact on the furnace structure and the internal stress of the melt. A smooth heating process helps to maintain uniform alloy composition, prevent local overheating or uneven cooling, and thus improve the quality of the final product.

[0067] Start the pressure monitoring system and record the current gas pressure P2; if P2 is lower than the preset minimum pressure Pl ow, the inert gas replenishment mechanism is triggered; this step ensures that the gas pressure in the furnace is always kept within a safe range during the entire heating process, preventing the intrusion of outside air and maintaining an effective gas protection layer. Continuous pressure monitoring can promptly detect and correct potential pressure shortages and ensure the safety and stability of the smelting environment.

[0068] Based on the recorded pressure value P2, the inert gas injection rate Q1 is adjusted; the formula is Q1 = k1*(P low-P2), where k1 is the proportional coefficient, which ensures that the gas pressure can quickly return to a safe range without causing overcompensation problems. This method not only improves the response speed, but also accurately controls the gas flow rate, making the pressure change in the furnace smoother, reducing the changes in the melt surface characteristics caused by pressure fluctuations, and further enhancing the effect of gas protection.

[0069] As the gas injection is adjusted, the temperature change ΔT1 in the furnace is monitored in real time, and the heating power W1 is fine-tuned according to ΔT1; the formula is W1=m1*ΔT1+n1, where m1 and n1 are preset parameters to ensure that the temperature rise meets the predetermined rate R1 and maintains a stable pressure level; this step ensures that the temperature rise meets the predetermined rate R1 and maintains a stable pressure level. By dynamically adjusting the heating power, fine control can be performed according to the actual temperature changes to avoid excessive temperature fluctuations that affect the stability of the smelting process. This method not only improves the accuracy of temperature control, but also optimizes energy utilization efficiency and reduces energy consumption.

[0070] Step 3: Based on the temperature and pressure conditions achieved in step 2, start the alloy raw material feeding mechanism, and dynamically adjust the inert gas flow rate while feeding to prevent the intrusion of external air; further comprising:

[0071] Set the alloy raw material feeding rate r1, and calculate the appropriate feeding cycle τ1 according to the current furnace temperature T2 and the target temperature Tf; the formula is τ1 = (Tf-T2) / (a1*r1), where a1 is the temperature influence coefficient, to ensure that the feeding process is coordinated with the temperature rise; this method can effectively avoid temperature fluctuations or changes in melt characteristics caused by improper feeding rate, and ensure the stability of temperature and alloy composition during the smelting process. A reasonable feeding rate helps maintain uniform heating in the furnace and reduce the risk of local overheating, thereby improving the quality and consistency of the final product.

[0072] Start the inert gas flow monitoring system and record the initial flow Q2; if the flow Q2 is detected to be lower than the preset minimum value Qmin, the flow adjustment mechanism is triggered; this step ensures that the inert gas flow is always kept within the safe range during the entire feeding process to prevent outside air from invading the furnace and destroying the gas protection layer. Continuous flow monitoring can timely detect and correct potential flow shortage problems and ensure the safety and effectiveness of the smelting environment.

[0073] Based on the recorded flow rate Q2, combined with the feeding rate r1, the inert gas flow rate Q3 is dynamically adjusted; the formula is Q3 = b1*r1+Q2, where b1 is the influencing factor of the feeding rate, ensuring that the gas flow rate is adjusted in time with the feeding rate changes; neither waste of resources due to excessive flow nor protection failure due to insufficient flow. This dynamic adjustment method can adapt to changes in smelting conditions in real time, provide more accurate and stable gas protection, and enhance the controllability and reliability of the smelting process.

[0074] As the flow rate is adjusted, the pressure P3 in the furnace is monitored in real time, and the gas replenishment amount S1 is fine-tuned according to the pressure change ΔP1; the formula is S1=c1*ΔP1+d1, where c1 and d1 are preset parameters to ensure that the pressure is maintained within a stable range [Pmin, Pmax] while preventing the intrusion of outside air. This step ensures that the pressure is maintained within a stable range [Pmin, Pmax] to avoid changes in the surface characteristics of the melt or failure of gas protection due to pressure fluctuations. By dynamically adjusting the gas replenishment amount, fine control can be performed according to the actual pressure changes to maintain the stability of the internal environment of the furnace, further prevent the intrusion of outside air, and improve the safety of the smelting process and product quality.

[0075] Step 4: As the raw materials in step 3 are completely melted, the surface characteristics of the melt are monitored, the surface state of the melt is evaluated by an optical sensing device, and the ratio of the inert gas composition is fine-tuned accordingly; further comprising:

[0076] Start the optical sensing device to continuously monitor the changes in the surface characteristics of the melt and record the initial reflectivity R2; when the raw material is completely melted, obtain the real-time reflectivity R3. This step provides real-time feedback on the surface state of the melt, ensuring that the dynamic changes in the melt characteristics during the smelting process can be accurately captured. The application of the optical sensing device makes monitoring more accurate and continuous, providing a reliable data basis for subsequent evaluation and adjustment. This real-time monitoring helps to detect potential problems in a timely manner and prevent quality defects caused by changes in melt characteristics.

[0077] Based on the recorded reflectivity change ΔR1=R3-R2, the melt surface state index S1 is evaluated; the formula is S1=e1*ΔR1+f1, where e1 and f1 are preset parameters to ensure accurate reflection of the melt surface characteristics; this method not only improves the accuracy of the evaluation, but also makes targeted adjustments based on the specific conditions of the melt surface, thereby optimizing the gas protection effect during the smelting process. Accurate state evaluation is the prerequisite for subsequent precise adjustments and helps to improve the quality of the final product.

[0078] According to the obtained state index S1, the inert gas composition adjustment amount ΔG1 is calculated; the formula is ΔG1 = g1*(S1-S0), where g1 is the proportional coefficient and S0 is the ideal state index. This step ensures that the adjustment of the inert gas composition matches the surface state of the melt, and neither wastes resources due to excessive components nor causes protection failure due to insufficient components. The introduction of the proportional coefficient g1 makes the adjustment more scientific and reasonable, and enhances the controllability and effectiveness of the adjustment process. In this way, the optimal gas protection environment can be maintained, and the stability of the smelting process and product quality can be improved.

[0079] After the composition adjustment is performed, the new reflectivity R4 of the melt surface is monitored, and the reflectivity difference ΔR2=R4-R3 before and after the adjustment is compared; if ΔR2 exceeds the preset range, the inert gas composition ratio is further fine-tuned until ΔR2 stabilizes in the optimal range. This step realizes closed-loop control of the inert gas composition, ensuring that each adjustment can achieve the expected effect. Through continuous optimization and adjustment, the surface characteristics of the melt can be kept in the best state, the effect of gas protection can be further enhanced, the risk of impurity introduction can be reduced, and the quality and performance of the alloy can be ultimately improved.

[0080] Step 5: Based on the surface state evaluation result of step 4, the melt stirring operation is performed, while keeping the flow direction of the inert gas coordinated with the airflow generated by the stirring to strengthen the protective barrier; further comprising:

[0081] According to the melt surface state index S1 obtained in step 4, the stirring rate v1 is determined; the formula is v1 = h1*S1+i1, where h1 and i1 are preset parameters to ensure that the stirring rate is adapted to the current melt surface characteristics; thereby avoiding changes in melt characteristics or failure of gas protection due to stirring too fast or too slow. This method not only improves the adaptability and accuracy of the stirring process, but also effectively reduces the unevenness of the melt surface and further optimizes the smelting environment.

[0082] Start the stirring device, operate it at the calculated rate v1, and record the initial inert gas flow direction θ2; at the same time, monitor the direction of the airflow generated by stirring θ3; this step provides basic data for subsequent adjustments and ensures the synchronization of the stirring operation and the inert gas flow. By monitoring the airflow direction in real time, potential incoordination problems can be discovered and corrected in a timely manner to ensure that the melt is always in the best protective environment during the stirring process. In addition, accurately recording the initial flow direction helps to evaluate the effect of subsequent adjustments.

[0083] Based on the recorded airflow direction θ3, the position of the inert gas injection point P1 is adjusted so that the gas flow direction θ4 is coordinated with the airflow direction θ3 generated by stirring; the formula is expressed as P1=j1*(θ3-θ2), where j1 is the adjustment coefficient, which ensures that the gas flow direction is synchronized with the stirring airflow and strengthens the protective barrier. This dynamic adjustment method can effectively prevent the intrusion of external air, maintain the stability of the melt surface and the effectiveness of gas protection. Synchronous gas flow and stirring airflow can also help improve the uniformity of melt mixing and improve alloy quality.

[0084] As the adjustment is completed, the changes in the melt surface reflectivity R5 and the gas flow direction θ are continuously monitored. If the reflectivity fluctuation ΔR3 or the gas flow direction deviation Δθ1 is found to exceed the set range, the gas injection point position P1 and the stirring rate v1 are fine-tuned until ΔR3 and Δθ1 stabilize within the optimal range. This step achieves closed-loop control of stirring and gas flow, ensuring that each adjustment achieves the desired effect. Through continuous optimization and adjustment, the melt surface characteristics and gas flow can always be kept in the best state, further enhancing the gas protection effect, and improving the safety of the smelting process and product quality.

[0085] Step 6: During the stirring process in step 5, a trace amount of active gas is introduced to improve the fluidity of the melt, but it is necessary to ensure that the content does not exceed a certain percentage of the total gas amount so as not to affect the protection effect; further comprising:

[0086] According to the melt surface reflectivity R5 and gas flow direction θ4 during the stirring operation in step 5, the timing of introducing the active gas is determined; when the reflectivity R5 is stable and the gas flow direction θ4 is as expected, the active gas injection system is started; this step ensures that the active gas is introduced under the most appropriate conditions to avoid affecting the melt characteristics and gas protection effect due to premature or late introduction. In this way, the role of the active gas can be maximized while maintaining the stability of the melt surface characteristics, providing the best conditions for subsequent operations.

[0087] Set the maximum allowable proportion of active gas L1, and calculate the maximum amount of active gas introduced Vact_max1 based on the current total gas volume Vtotal l 1; the formula is Vact_max1 = L1 * Vtotal l 1, to ensure that the active gas content does not exceed a certain percentage; thereby avoiding negative impacts on the inert gas protective layer. The setting of the maximum allowable proportion L1 provides a safety limit to prevent melt oxidation or other adverse reactions caused by excessive introduction of active gas, thereby ensuring the safety and stability of the smelting process.

[0088] After execution, active gas is gradually introduced, and the melt fluidity index F1 is monitored at the same time; the formula is F1=k2*(Vact1 / Vtotal 1), where k2 is the preset parameter, Vact1 is the actual amount of active gas introduced, and this formula is used to evaluate the fluidity improvement effect; this method not only improves the controllability and accuracy of the introduction process, but also can evaluate the fluidity improvement effect in real time, adjust the introduction rate in time, and ensure that the melt fluidity reaches the ideal state, thereby optimizing the smelting efficiency and product quality.

[0089] As the active gas is introduced, the changes in the melt temperature T3 and pressure P4 are monitored in real time. If abnormal fluctuations ΔT2 or ΔP2 are found to be beyond the safe range, the rate of active gas introduction is slowed down until ΔT2 and ΔP2 return to the normal range, while keeping F1 within the ideal range. This step achieves closed-loop control of temperature and pressure to ensure that each adjustment achieves the expected effect. By dynamically adjusting the introduction rate, fine control can be performed according to actual changes to maintain the stability of the furnace environment, further enhance the gas protection effect, and improve the safety and reliability of the smelting process.

[0090] Step 7: continuing the smelting process according to the active gas concentration set in step 6, tracking the gas dissolution in the melt in real time, and adjusting the active gas input rate according to the solubility change; further comprising:

[0091] According to the active gas concentration L1 set in step 6, the real-time gas solubility monitoring system is started to record the initial solubility D1; as the smelting process continues, the gas dissolution in the melt is continuously tracked; this step provides the baseline data for the subsequent tracking of solubility changes, ensuring accurate monitoring of the gas dissolution in the melt. By continuously tracking the solubility changes, the changing trend of the solubility can be discovered and responded to in a timely manner, avoiding changes in melt characteristics or quality problems caused by abnormal solubility.

[0092] Based on the recorded initial solubility D1, calculate the current solubility change ΔD2; the formula is ΔD2 = D2-D1, where D2 is the solubility measured in real time, ensuring accurate capture of the solubility change trend; this step ensures accurate capture of solubility changes and reflects the actual dissolution of gas in the melt during the smelting process. By measuring and calculating solubility changes in real time, the melt state can be evaluated more scientifically, providing a reliable basis for subsequent adjustments, thereby optimizing gas management during the smelting process.

[0093] According to the obtained solubility change ΔD2, the active gas input rate Ri n1 is adjusted; the formula is Ri n1 = m2*ΔD2 + n2, where m2 and n2 are preset parameters, which ensure that the input rate is dynamically adjusted with the solubility change to maintain the ideal dissolution state; this method not only improves the accuracy of input rate adjustment, but also can flexibly respond to actual solubility changes, ensuring that the gas content inside the melt is always in the best state, further improving the stability of the smelting process and product quality.

[0094] After executing the rate adjustment, monitor the changes in the melt temperature T4 and pressure P5, and evaluate the total active gas content Vact2; if it is found that the temperature or pressure fluctuations ΔT3, ΔP3 exceed the safe range, or Vact2 exceeds the maximum allowable ratio L1, fine-tune Ri n1 until ΔT3, ΔP3 return to the normal range and Vact2 remains within the ideal range. This step realizes closed-loop control of temperature, pressure and gas content to ensure that each adjustment can achieve the expected effect. Through continuous optimization and adjustment, the melt temperature, pressure and gas content can always be kept in a safe and stable range, further enhancing the gas protection effect and improving the safety and reliability of the smelting process.

[0095] Step 8: When approaching the scheduled end time of smelting, gradually lower the temperature and simultaneously reduce the inert gas supply, but still maintain a sufficient covering layer to prevent the melt from being directly exposed to the air; further comprising:

[0096] Set the scheduled melting end time Tend1, and calculate the remaining time Δt1=Tend1-t1 according to the current time t1; when Δt1 enters the preset cooling preparation stage, start the temperature and gas supply adjustment program; this step provides a clear time reference for the cooling stage of the melting process, ensuring that subsequent operations can be carried out in an orderly manner when approaching the scheduled end time. In this way, the problem of excessive temperature gradient caused by sudden cooling can be avoided, the impact on the melt and furnace structure can be reduced, and the safety and stability of the melting process can be ensured.

[0097] Based on the determined time point for entering the cooling preparation stage, the furnace heating power P2 is gradually reduced; the formula is P2 = a2*(1-Δt1 / Δt_max1), where a2 is the initial heating power and Δt_max1 is the total time from the start of cooling to the end of smelting, ensuring a steady temperature drop; this method not only achieves a gradual temperature drop, but also effectively prevents stress concentration in the melt or uneven local cooling caused by rapid cooling. A steady cooling process helps maintain the uniformity of the alloy composition and improves the quality of the final product.

[0098] While executing, the inert gas supply Vg1 is reduced synchronously; the formula is expressed as Vg1 = b2*(1-Δt1 / Δt_max1), where b2 is the initial inert gas supply, to ensure that the inert gas supply matches the temperature reduction process and maintains a stable environment inside the melt; by dynamically adjusting the inert gas supply, sufficient coverage can be maintained during the cooling process to prevent the melt from being directly exposed to the air and avoid the risk of oxidation and other impurities being introduced. This synchronous adjustment method enhances the effect of gas protection and improves the safety and reliability of the smelting process.

[0099] As the gas supply is adjusted, the changes in the internal pressure P6 and temperature T5 of the melt are continuously monitored; if the pressure or temperature fluctuations ΔP4 and ΔT4 are found to be beyond the safe range, the heating power P2 and the inert gas supply Vg1 are fine-tuned until ΔP4 and ΔT4 return to the normal range to ensure the safety and stability of the entire cooling process. This step realizes closed-loop control of temperature and pressure to ensure that each adjustment can achieve the expected effect. Through continuous optimization and adjustment, the melt temperature and pressure can always be kept within a safe and stable range, further enhancing the gas protection effect, and improving the safety of the smelting process and product quality.

[0100] Step 9: After the temperature reduction in step 8 is completed, a cooling procedure is performed, and an inert gas environment is maintained throughout the process until the alloy is completely solidified, and finally the remaining protective gas is safely discharged to complete the entire smelting process; further comprising:

[0101] According to the furnace temperature Tf1 after cooling in step eight, set the starting conditions of the cooling program; start the cooling system and record the initial inert gas environment parameters, including pressure P7 and gas composition ratio G1; this step provides a clear starting point and benchmark data for the subsequent cooling process to ensure that the cooling program can proceed in an orderly manner. In this way, changes in alloy properties or quality problems caused by improper cooling conditions can be avoided, ensuring the safety and effectiveness of the cooling process.

[0102] Based on the recorded initial environmental parameters, the cooling rate Rc1 is gradually increased; the formula is Rc1 = c2*(Tf1-Tc1), where c2 is the preset coefficient and Tc1 is the critical temperature required for alloy solidification, ensuring that the cooling process is smooth and not too fast to affect the quality of the alloy; this method not only achieves a gradual increase in the cooling rate, but also effectively prevents internal stress concentration or crack formation caused by too fast cooling. A smooth cooling process helps maintain the integrity of the alloy structure and the consistency of performance, improving the quality of the final product.

[0103] With the adjustment of cooling rate, the solidification progress of the alloy I1 is monitored in real time; the formula is expressed as I1 = d2*Δt2+e2, where d2 and e2 are preset parameters, and Δt2 is the actual time difference from the beginning of cooling to the solidification of the alloy, ensuring accurate judgment of the solidification state of the alloy; by real-time monitoring of the solidification progress, possible problems in the solidification process can be discovered and responded to in time, ensuring that the alloy is completely solidified before the next step. This dynamic monitoring method improves the controllability and reliability of the solidification process and ensures the quality and performance of the alloy.

[0104] Perform solidification monitoring. When it is detected that the alloy is completely solidified, that is, the solidification progress I1 reaches 100%, start the safe discharge procedure of the remaining protective gas; then, monitor the pressure change ΔP5 inside the furnace; if ΔP5 exceeds the safe discharge range, adjust the discharge rate Ve1 until ΔP5 stabilizes in the safe range; the formula is Ve1 = f2*ΔP5 + g2, where f2 and g2 are preset parameters to ensure that the discharge process is both fast and safe. This step realizes closed-loop control of the discharge process, ensuring that each adjustment can achieve the expected effect. Through continuous optimization and adjustment, the internal pressure of the furnace can always be kept within the safe range, further enhancing the safety and environmental protection of gas emissions.

[0105] In summary, this method is able to achieve real-time monitoring and dynamic adjustment of the gas composition during the smelting process. Through this method, the ratio of inert gas and active gas can be accurately controlled according to the surface characteristics and solubility changes of the melt at different stages of smelting (such as heating, feeding, stirring, introduction of active gas, etc.) to ensure the best gas protection effect. Specifically, this method can significantly reduce the risk of impurity introduction, improve melt fluidity, and ultimately improve the quality and performance of the alloy. In addition, the inert gas environment is maintained throughout the process until the alloy is completely solidified, and the remaining protective gas is safely discharged, further ensuring the safety and environmental protection of the smelting process.

[0106] Finally, it should be noted that the above is only a preferred embodiment of the present invention and is not intended to limit the present invention. Although the present invention has been described in detail with reference to the aforementioned embodiments, it is still possible for those skilled in the art to modify the technical solutions described in the aforementioned embodiments or to make equivalent substitutions for some of the technical features therein. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principles of the present invention should be included in the protection scope of the present invention.

Claims

1. A method for optimizing gas protection in a magnesium alloy smelting process, characterized in that: The following steps are involved: Prepare the smelting environment, ensure that the furnace is clean and free of impurities, and then inject basic inert gas to form a preliminary protective atmosphere; In the initial protective atmosphere, the temperature is gradually raised to the preset temperature. During this period, the gas pressure is continuously monitored, and inert gas is added in time to maintain a stable pressure level. Based on the temperature and pressure conditions reached, the alloy raw material feeding mechanism is started, and the inert gas flow rate is dynamically adjusted while feeding; As the alloy raw materials are completely melted, the changes in the surface characteristics of the melt are monitored, and the surface state of the melt is evaluated through an optical sensing device, and the inert gas composition ratio is fine-tuned accordingly; According to the surface state evaluation results, the melt stirring operation is carried out, while the flow direction of the inert gas is coordinated with the airflow generated by the stirring, and the active gas is introduced during the stirring process; Continue the smelting process according to the set active gas concentration, track the gas dissolution in the melt in real time, and adjust the active gas input rate according to the solubility change; When approaching the scheduled end time of smelting, the temperature is gradually lowered and the supply of inert gas is reduced simultaneously. After the temperature is lowered, the cooling procedure is executed and the inert gas environment is maintained throughout the process until the alloy is completely solidified. Finally, the remaining protective gas is safely discharged to complete the entire smelting process.

2. The method for optimizing gas protection in a magnesium alloy smelting process according to claim 1, characterized in that: The formation of a preliminary protective atmosphere includes: Determine the cleanliness index of the furnace interior, obtain the thickness of the residue on the furnace inner wall through the detection device, and if the thickness is greater than the set threshold, start the automatic cleaning program until the thickness meets the standard; Based on the cleanliness index obtained, calculate the basic inert gas injection amount to ensure that the injection amount is suitable for the current cleaning status; Start the gas injection system to evenly distribute the calculated basic inert gas volume in the furnace space, monitor the pressure in the furnace, and record the initial pressure value; According to the initial pressure value, the gas flow controller is adjusted to keep the pressure in the furnace stable within the target range.

3. The method for optimizing gas protection in a magnesium alloy smelting process according to claim 2, characterized in that: In the initial protective atmosphere, the temperature is gradually raised to a preset temperature, the gas pressure is continuously monitored, and inert gas is supplemented in time to maintain a stable pressure level, including: Set the preheating rate, calculate the required heating time based on the initial furnace temperature and target temperature, start the pressure monitoring system, and record the current gas pressure; if the pressure is lower than the preset minimum value, the inert gas replenishment mechanism is triggered; Based on the recorded pressure value, adjust the inert gas injection rate to ensure that the gas pressure quickly returns to a safe range; As gas injection is adjusted, the temperature changes in the furnace are monitored in real time, and the heating power is fine-tuned according to the changes to ensure that the temperature rise meets the predetermined rate.

4. The method for optimizing gas protection in a magnesium alloy smelting process according to claim 3, characterized in that: Based on the temperature and pressure conditions reached, the alloy raw material feeding mechanism is started, and the inert gas flow rate is dynamically adjusted while feeding, including: Set the alloy raw material feeding rate, calculate the feeding cycle according to the current furnace temperature and target temperature, and ensure that the feeding process is coordinated with the temperature rise; Start the inert gas flow monitoring system and record the initial flow rate; if the flow rate is detected to be lower than the preset minimum value, the flow adjustment mechanism is triggered; Based on the recorded flow rate and combined with the feeding rate, the inert gas flow rate is dynamically adjusted to ensure that the gas flow rate is adjusted in time with the feeding rate changes; As the flow rate is adjusted, the pressure in the furnace is monitored in real time, and the amount of gas replenishment is fine-tuned according to pressure changes.

5. The method for optimizing gas protection in a magnesium alloy smelting process according to claim 4, characterized in that: As the alloy raw materials are completely melted, the changes in the surface characteristics of the melt are monitored, the surface state of the melt is evaluated by an optical sensing device, and the ratio of the inert gas composition is fine-tuned accordingly, including: Start the optical sensing device to continuously monitor the changes in the surface characteristics of the melt and record the initial reflectivity; when the raw material is completely melted, obtain the real-time reflectivity; Based on the recorded reflectivity changes, the melt surface condition indicators are evaluated to ensure accurate reflection of the melt surface characteristics; According to the obtained state index, the inert gas composition adjustment amount is calculated to ensure that the inert gas composition matches the melt surface state; After the composition adjustment is performed, the new reflectivity of the melt surface is monitored and the reflectivity difference before and after the adjustment is compared; if it exceeds the preset range, the inert gas composition ratio is further fine-tuned.

6. The method for optimizing gas protection in a magnesium alloy smelting process according to claim 5, characterized in that: The step of performing melt stirring operation based on the surface state evaluation result while keeping the flow direction of the inert gas coordinated with the airflow generated by the stirring comprises: According to the melt surface state index obtained, the stirring rate is determined to ensure that the stirring rate is adapted to the current melt surface characteristics; Start the stirring device, operate it at the calculated rate, and record the initial inert gas flow direction; at the same time, monitor the direction of the gas flow generated by the stirring; Based on the recorded airflow direction, adjust the position of the inert gas injection point so that the gas flow direction is coordinated with the airflow direction generated by stirring, ensuring that the gas flow direction is synchronized with the stirring airflow; As adjustments are made, the changes in the reflectivity of the melt surface and the direction of the gas flow are continuously monitored. If fluctuations are found to be outside the set range, the gas injection point position and stirring rate are fine-tuned.

7. The method for optimizing gas protection in a magnesium alloy smelting process according to claim 6, characterized in that: The process of introducing active gas during stirring comprises: Determine the timing of introducing active gas based on the melt surface reflectivity and gas flow direction during stirring operation; start the active gas injection system when the reflectivity is stable and the gas flow direction is as expected; Set the maximum allowable ratio of active gas, calculate the maximum amount of active gas introduced based on the current total gas volume, and ensure that the active gas content does not exceed a certain percentage; After execution, active gas is gradually introduced while monitoring melt fluidity indicators to evaluate the fluidity improvement effect; As the active gas is introduced, the changes in melt temperature and pressure are monitored in real time. If abnormal fluctuations are found to exceed the safe range, the rate of active gas introduction is slowed down until it returns to the normal range.

8. The method for optimizing gas protection in a magnesium alloy smelting process according to claim 7, characterized in that: The step of adjusting the active gas input rate according to the solubility change comprises: According to the set active gas concentration, the real-time gas solubility monitoring system is started to record the initial solubility; as the smelting process continues, the gas dissolution in the melt is continuously tracked; Based on the recorded initial solubility, calculate the current solubility change to ensure accurate capture of the solubility change trend; According to the obtained solubility change, the input rate of the active gas is adjusted to ensure that the input rate is dynamically adjusted with the solubility change; After the rate adjustment is performed, the changes in melt temperature and pressure are monitored, and the total content of active gases is evaluated; if it is found that the temperature or pressure fluctuations exceed the safe range, or the total content of active gases exceeds the maximum allowable ratio, the input rate is fine-tuned until it returns to the normal range.

9. The method for optimizing gas protection in a magnesium alloy smelting process according to claim 8, characterized in that: When approaching the predetermined smelting end time, gradually lowering the temperature and simultaneously reducing the inert gas supply amount comprises: Set the scheduled smelting end time, and calculate the remaining time based on the current time; when the remaining time enters the preset cooling preparation stage, start the temperature and gas supply adjustment program; Based on the determined time point for entering the cooling preparation phase, gradually reduce the furnace heating power to ensure a steady temperature drop; During the execution, the inert gas supply is reduced synchronously to ensure that the inert gas supply matches the temperature reduction process and maintain a stable environment in the melt; As the gas supply is adjusted, the changes in pressure and temperature inside the melt are continuously monitored; if it is found that the pressure or temperature fluctuations exceed the safe range, the heating power and inert gas supply are fine-tuned until they return to the normal range.

10. The method for optimizing gas protection in a magnesium alloy smelting process according to claim 9, characterized in that: The cooling process is performed to maintain an inert gas environment until the alloy is completely solidified, including: According to the furnace temperature after warming, set the initial conditions of the cooling program; start the cooling system and record the initial inert gas environment parameters, including pressure and gas composition ratio; Based on the recorded initial environmental parameters, the cooling rate is gradually increased. As the cooling rate is adjusted, the solidification progress of the alloy is monitored in real time to ensure accurate judgment of the alloy solidification state. Perform solidification monitoring. When it is detected that the alloy is fully solidified, that is, the solidification progress reaches 100%, start the safe discharge procedure of the remaining protective gas; then, monitor the pressure changes inside the furnace; if it exceeds the safe discharge range, adjust the discharge rate until it stabilizes within the safe range.

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