Regenerated aluminum alloy ingot manufacturing process with precise component regulation and control

Abstract

The invention provides a secondary aluminum alloy ingot manufacturing process with precise component regulation and control, and relates to the technical field of secondary aluminum alloy ingot manufacturing, the secondary aluminum alloy ingot manufacturing process comprises the following steps: collecting waste aluminum materials, and classifying and sorting the collected waste aluminum materials to form qualified furnace charge; the qualified furnace charge with the actual volume larger than the preset volume in the qualified furnace charge is put into a main chamber of a smelting furnace to be smelted, and slagging-off and alloy component adjustment are conducted on the liquid aluminum alloy; and the liquid aluminum alloy subjected to drossing and alloy component adjustment is subjected to hydrogen removal and impurity removal treatment, and the refined and purified liquid aluminum alloy is poured into a casting mold to be manufactured into a regenerated aluminum alloy ingot with a certain shape and specification. According to the method, waste aluminum of different types, purities and shapes is pretreated to different degrees, the waste aluminum with the high impurity content is removed, meanwhile, furnace materials of different sizes are fed into the corresponding smelting chambers, and metal burning loss caused by the fact that qualified furnace materials such as cutting materials with the actual size smaller than the preset size are prone to burning loss due to the fact that the temperature of the main chamber is too high is avoided.

Description

Technical Field

[0001] The present invention belongs to the technical field of manufacturing recycled aluminum alloy ingots, and particularly relates to a manufacturing process for recycled aluminum alloy ingots with precise composition control. Background Art

[0002] Recycled aluminum alloy ingots refer to aluminum alloy products with certain compositions and shapes made from waste aluminum through recycling treatment, smelting, and casting processes. Recycled aluminum alloy ingots are usually used to manufacture various aluminum alloy products and components, such as aerospace equipment, automotive parts, building materials, electronic products, etc. Due to the relatively energy-saving, environmentally friendly, and low-cost production process of recycled aluminum alloy ingots, they are widely used in industrial production under the increasing awareness of environmental protection. During the production process of recycled aluminum alloy ingots, the recycled waste aluminum is usually poured into the melting furnace for melting after being cleaned and dried at one time. However, not all of the recycled waste aluminum is pure aluminum. If it is melted directly without classification, it will result in more impurities in the finally cast recycled aluminum alloy ingots. At the same time, due to the different sizes of the waste aluminum poured into the melting furnace, it is very likely that some small-sized waste aluminum, such as cutting materials, will be burned due to the high temperature and long melting time, causing material waste. Summary of the Invention

[0003] The present invention provides a manufacturing process for recycled aluminum alloy ingots with precise composition control to solve at least one of the above-mentioned technical problems.

[0004] To solve the above technical problems, the present invention discloses a manufacturing process for recycled aluminum alloy ingots with precise composition control, including the following steps: S1. Collect waste aluminum materials, classify and sort the collected waste aluminum materials to form several groups of waste aluminum to be processed, and pre-treat the several groups of waste aluminum to be processed to form qualified furnace charges. S2. Put the qualified furnace charges with an actual volume greater than the preset volume in the main chamber of the melting furnace for melting, and put the qualified furnace charges with an actual volume less than the preset volume in the side chamber of the melting furnace for melting to form liquid aluminum alloy, and perform slag skimming and alloy composition adjustment on the liquid aluminum alloy. S3. Perform hydrogen removal and impurity removal treatment on the liquid aluminum alloy after slag skimming and alloy composition adjustment to remove hydrogen and solid inclusions in the liquid aluminum alloy, pour the refined and purified liquid aluminum alloy into a casting mold to manufacture recycled aluminum alloy ingots with a certain shape and specification, and perform appearance quality inspection and rejection on the cooled and solidified recycled aluminum alloy ingots.

[0005] Preferably, the pre-treatment of the several groups of waste aluminum to be processed includes: Use a crushing device to preliminarily disassemble and crush several groups of waste aluminum to be processed, forming several groups of furnace charge blocks that are convenient for processing. Send the several groups of furnace charge blocks into a magnetic separator respectively, and remove the furnace charge blocks containing magnetic metals in the furnace charge blocks through the magnetic separator. Put the several groups of furnace charge blocks after magnetic separation into a flotation device in sequence, add a flotation medium to the flotation device, adjust the density of the flotation liquid in the flotation device to an appropriate value, and remove the organic matter lighter than aluminum and other metal furnace charge blocks heavier than aluminum through the flotation device. Wash the furnace charge blocks after flotation through a high-pressure water spray cleaning device, wash down the flotation medium for recycling, and dry the furnace charge blocks after cleaning through a drying device to form qualified furnace charge.

[0006] Preferably, the adjustment of the alloy composition of the liquid aluminum alloy includes: S30. Use a direct-reading spectrometer to conduct in-furnace composition analysis on the liquid aluminum alloy to obtain an in-furnace composition analysis table of the liquid aluminum alloy; S31. Calculate the final required feeding amount for alloy composition adjustment based on the in-furnace composition analysis table of the liquid aluminum alloy and verify it.

[0007] Preferably, calculating the final required feeding amount for alloy composition adjustment based on the in-furnace composition analysis table of the liquid aluminum alloy and verifying it includes: S310. Based on the percentage of the content of the element with an excessive content in the in-furnace composition analysis table of the liquid aluminum alloy calculate the preset required feeding amount: (1); Wherein, is the preset required feeding amount calculated based on the percentage of the content of the element with an excessive content in the in-furnace composition analysis table of the liquid aluminum alloy , is the total mass of the original liquid aluminum alloy, is the percentage of the content of the element with an excessive content in the in-furnace composition analysis table of the liquid aluminum alloy , is the preset qualified content percentage of the element in the liquid aluminum alloy ; S311. Based on the calculated preset required feeding amount and the percentage of the content of the element with insufficient content in the in-furnace composition analysis table of the liquid aluminum alloy calculate the final required feeding amount for alloy composition adjustment: (2); Wherein, is the final required feeding amount for alloy composition adjustment, is the preset qualified content percentage of the element in the liquid aluminum alloy , The insufficient elements in the liquid aluminum alloy pre-furnace composition analysis table The percentage of element content, To supplement Elements added Element alloy The content percentage of the element.

[0008] Preferably, the method further includes verifying the feeding amount: S312, adjusting the final required feed amount based on the calculated alloy composition , calculate the required feed amount The percentage of the remaining elements in the adjusted liquid aluminum alloy: (3); in, According to the required feed amount The percentage of the content of the i-th element in the remaining elements in the adjusted liquid aluminum alloy, is the content percentage of the i-th element in the rest of the elements in the liquid aluminum alloy pre-furnace composition analysis table, The percentage of the i-th element in the remaining elements in the aluminum material used to adjust the alloy composition; S313, if , then the verification is successful, otherwise, the final required feed amount is recalculated to adjust the alloy composition, where According to the required feed amount The preset minimum qualified content percentage of the i-th element among the remaining elements in the adjusted liquid aluminum alloy, According to the required feed amount The preset qualified maximum percentage of the ith element among the remaining elements in the adjusted liquid aluminum alloy.

[0009] Preferably, the refining and purification includes introducing a mixed gas of nitrogen, argon and chlorine into the aluminum melt to achieve the effect of removing hydrogen, and using any one of a foam ceramic filter, a ceramic filter or a particle packed bed to filter the liquid aluminum alloy to achieve the impurity removal effect.

[0010] Preferably, the method further comprises evaluating the dehydrogenation effect within a preset time period before the end of the refining and purification: Calculate the actual evaluation coefficient of hydrogen removal effect: (4); in, is the actual evaluation coefficient of hydrogen removal effect, is the hydrogen concentration of the liquid aluminum alloy before dehydrogenation, is the hydrogen concentration on the surface of liquid aluminum alloy during the evaluation of dehydrogenation effect, is the average ventilation volume of the mixed gas per unit time, is the mass transfer coefficient of hydrogen in liquid aluminum alloy, is the solubility of hydrogen in liquid aluminum alloy, is the density of liquid aluminum alloy, is the reference concentration of hydrogen in liquid aluminum alloy when the hydrogen removal effect is qualified, is the average preset velocity of hydrogen floating during the hydrogen removal process, is the hydrogen removal time; When the actual evaluation coefficient of the hydrogen removal effect is greater than the preset evaluation coefficient of the hydrogen removal effect, it proves that the hydrogen removal effect is qualified.

[0011] Preferably, the recycled aluminum alloy ingots after cooling and solidification are inspected, including mechanical property testing and surface quality testing, and the comprehensive mechanical property evaluation coefficient and the comprehensive surface quality evaluation coefficient of this batch of recycled aluminum alloy ingots are obtained respectively; The mechanical properties of this batch of recycled aluminum alloy ingots are tested by using a tensile testing machine, a Brinell hardness tester and an impact testing machine; The surface quality of this batch of recycled aluminum alloy ingots is tested by using a scanner.

[0012] Compared with the prior art, the present invention has the following beneficial effects: The present invention differentiates waste aluminum of different types, purities and shapes to form several groups of waste aluminum to be processed, so that waste aluminum of different types, purities and shapes can be pretreated to different degrees, and waste aluminum with high impurity content can be removed. Not only can non-aluminum materials be removed through classified targeted pretreatment, but also the pretreatment efficiency can be improved, greatly avoiding material loss during the pretreatment process. Qualified furnace charges with an actual volume greater than the preset volume in the qualified furnace charges are put into the main chamber of the melting furnace for melting, and qualified furnace charges with an actual volume less than the preset volume are put into the side chamber of the melting furnace for melting to avoid metal burning of furnace charges such as cutting materials that are prone to burning due to the too high temperature in the main chamber. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] The drawings are used to provide a further understanding of the present invention, and constitute a part of the specification. Together with the embodiments of the present invention, they are used to explain the present invention and do not constitute a limitation to the present invention. In the drawings: Figure 1 is a schematic process flow diagram of the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0014] The following describes the preferred embodiments of the present invention with reference to the drawings. It should be understood that the preferred embodiments described herein are only for explaining and illustrating the present invention, and are not used to limit the present invention.

[0015] In addition, in the present invention, descriptions such as "first", "second", etc. are only for descriptive purposes, and do not particularly refer to the meaning of order or sequence, nor are they used to limit the present invention. They are merely used to distinguish components or operations described with the same technical terms, and should not be construed as indicating or implying their relative importance or implicitly indicating the quantity of the indicated technical features. Thus, features defined as "first" and "second" may explicitly or implicitly include at least one such feature. In addition, the technical solutions and technical features between various embodiments can be combined with each other, but it must be based on the ability of those of ordinary skill in the art to implement. When the combination of technical solutions results in contradictions or cannot be implemented, it should be considered that such a combination of technical solutions does not exist and is not within the scope of protection required by the present invention.

[0016] The present invention provides the following embodiments Embodiment 1 An embodiment of the present invention provides a manufacturing process for a regenerated aluminum alloy ingot with precise component control, as Figure 1 shown, including the following steps: S1. Collect waste aluminum materials, classify and sort the collected waste aluminum materials to form several groups of waste aluminum to be processed, and perform pretreatment on the several groups of waste aluminum to be processed to form qualified furnace charges; S2. Put the qualified furnace charges with an actual volume greater than the preset volume in the qualified furnace charges into the main chamber of the melting furnace for melting, and put the qualified furnace charges with an actual volume less than the preset volume in the qualified furnace charges into the side chamber of the melting furnace for melting to form liquid aluminum alloy, and perform slag skimming and alloy component adjustment on the liquid aluminum alloy; S3. Perform hydrogen removal and impurity removal treatment on the liquid aluminum alloy after slag skimming and alloy component adjustment to remove hydrogen and solid inclusions in the liquid aluminum alloy, pour the refined and purified liquid aluminum alloy into a casting mold to manufacture a regenerated aluminum alloy ingot with a certain shape and specification, and perform appearance quality inspection and rejection on the regenerated aluminum alloy ingot after cooling and solidification.

[0017] The working principle and beneficial effects of the above technical solution are as follows: First, the recycled waste aluminum is distinguished and grouped, and then different degrees of pretreatment are performed on several groups of waste aluminum to be processed to form qualified furnace charges. The qualified furnace charges with an actual volume greater than the preset volume in the qualified furnace charges are put into the main chamber of the melting furnace for melting, and the qualified furnace charges with an actual volume less than the preset volume in the qualified furnace charges are put into the side chamber of the melting furnace for melting to form liquid aluminum alloy. Then, the liquid aluminum alloy is purified, and the refined and purified liquid aluminum alloy is poured into a casting mold to manufacture regenerated aluminum alloy ingots of various shapes and specifications. Finally, the regenerated aluminum alloy ingots are inspected and rejected; The present invention differentiates waste aluminum of different types, purities, and shapes to form several groups of waste aluminum to be processed, so that waste aluminum of different types, purities, and shapes can be pretreated to different degrees, and waste aluminum with high impurities is removed. Not only can non-aluminum materials be removed through targeted classification pretreatment, but also the pretreatment efficiency can be improved, greatly avoiding material loss during the pretreatment process. Qualified furnace charges with an actual volume greater than the preset volume in the qualified furnace charges are put into the main chamber of the melting furnace for melting, and qualified furnace charges with an actual volume less than the preset volume are put into the side chamber of the melting furnace for melting to avoid metal burning of easily burned furnace charges such as cutting materials with an actual volume less than the preset volume due to the too high temperature in the main chamber.

[0018] Example 2 On the basis of Example 1, the pretreatment of several groups of waste aluminum to be processed is carried out, including: Using crushing equipment to respectively carry out preliminary disassembly and crushing on several groups of waste aluminum to be processed to form several groups of furnace charge blocks convenient for processing. The several groups of furnace charge blocks are respectively sent into a magnetic separator, and the furnace charge blocks containing magnetic metals in the furnace charge blocks are removed by the magnetic separator. The several groups of furnace charge blocks after magnetic separation are respectively and sequentially put into a flotation device, a flotation medium is added to the flotation device, the density of the flotation liquid in the flotation device is adjusted to an appropriate value, and organic substances lighter than aluminum and other metal furnace charge blocks heavier than aluminum are removed by the flotation device. The furnace charge blocks after flotation are cleaned by a high-pressure water spray cleaning device, the flotation medium is washed off and recycled, and the furnace charge blocks after cleaning are dried by a drying device to form qualified furnace charges.

[0019] The working principle and beneficial effects of the above technical solution are: By pretreating several groups of waste aluminum to be processed, the oil and impurity on the surface of the waste aluminum to be processed can be removed, and at the same time, the waste aluminum to be processed containing other metal impurities can also be removed, so as to ensure the purity of the qualified furnace charges and greatly improve the quality of the final recycled aluminum alloy ingot; Since the basic conditions of different waste aluminum to be processed are different, there will be differences in the time required for each step of processing into qualified furnace charges. Pretreating different groups of waste aluminum to be processed separately can increase the pretreatment efficiency, and at the same time ensure that the pretreatment degree of each group of waste aluminum to be processed remains within an appropriate pretreatment degree, greatly improving the production efficiency while ensuring the quality of the final product.

[0020] Example 3 On the basis of Example 1, the adjustment of the alloy composition of the liquid aluminum alloy includes: S30. Using a direct-reading spectrometer to perform in-furnace composition analysis on the liquid aluminum alloy to obtain an in-furnace composition analysis table of the liquid aluminum alloy; S31. Calculating the final required feeding amount for alloy composition adjustment based on the in-furnace composition analysis table of the liquid aluminum alloy and verifying it.

[0021]

[0022] Liquid aluminum alloy in-furnace composition analysis table The working principle and beneficial effects of the above technical solution are as follows: A spectral analyzer is used to perform in-furnace composition analysis on liquid aluminum alloy to obtain a liquid aluminum alloy in-furnace composition analysis table. Based on the liquid aluminum alloy in-furnace composition analysis table, the final required feeding amount for alloy composition adjustment is calculated. The final required feeding amount for alloy composition adjustment is the final mass of the aluminum material input for alloy composition adjustment. After that, the final required feeding amount for alloy composition adjustment is verified, and feeding is carried out after verification to ensure the content of each element in the final recycled aluminum alloy, thereby ensuring the product quality of the recycled aluminum alloy.

[0023] Example 4 On the basis of Example 3, the final required feeding amount for alloy composition adjustment is calculated based on the liquid aluminum alloy in-furnace composition analysis table and verified, including: S310. Based on the percentage of the element content of the element with an excessive content in the liquid aluminum alloy in-furnace composition analysis table calculate the preset required feeding amount: (1); Among them, is the preset required feeding amount calculated based on the percentage of the element content of the element with an excessive content in the liquid aluminum alloy in-furnace composition analysis table (i.e., the preset mass of the aluminum material input for alloy composition adjustment), is the total mass of the original liquid aluminum alloy, is the percentage of the element content of the element with an excessive content in the liquid aluminum alloy in-furnace composition analysis table is the preset qualified content percentage of the element in the liquid aluminum alloy; is the liquid aluminum alloy preset qualified content percentage of the element; S311. Based on the calculated preset required feeding amount and the percentage of the element content of the element with insufficient content in the liquid aluminum alloy in-furnace composition analysis table calculate the final required feeding amount for alloy composition adjustment: (2); Among them, is the final required feeding amount for alloy composition adjustment (i.e., the final mass of the aluminum material input for alloy composition adjustment), is the preset qualified content percentage of the element in the liquid aluminum alloy, is the percentage of the element content of the element with insufficient content in the liquid aluminum alloy in-furnace composition analysis table is the element, is for supplementing When adding elements in the element alloy The percentage content of the element (if the element is magnesium, then the element alloy is a magnesium ingot); It also includes verification of the feeding amount: S312. Adjust the final required feeding amount based on the calculated alloy composition , and calculate the percentage content of the remaining elements in the liquid aluminum alloy after adjustment according to the required feeding amount : (3); Among them, is the percentage content of the i-th element among the remaining elements in the liquid aluminum alloy after adjustment according to the required feeding amount , is the percentage content corresponding to the i-th element among the remaining elements in the pre-furnace composition analysis table of the liquid aluminum alloy is the percentage content corresponding to the i-th element among the remaining elements in the aluminum material input for alloy composition adjustment (the remaining elements are the remaining elements in the liquid aluminum alloy except for the over-standard elements and the under-standard elements , and the "remaining elements" in the above , and correspond to each other. If the i-th element is iron, then , and the remaining elements in are all iron elements); S313. If , it proves that the verification is successful (that is, feeding the aluminum material according to the component can achieve alloy composition adjustment), otherwise, recalculate the final required feeding amount for alloy composition adjustment, where is the minimum percentage of the preset qualified content of the i-th element among the remaining elements in the liquid aluminum alloy after adjustment according to the required feeding amount , is the maximum percentage of the preset qualified content of the i-th element among the remaining elements in the liquid aluminum alloy after adjustment according to the required feeding amount .

[0024] The working principle and beneficial effects of the above technical solution: First, calculate the preset required feeding amount based on the percentage content of the over-standard elements in the pre-furnace composition analysis table of the liquid aluminum alloy, and then based on the calculated preset required feeding amount and the under-standard elements in the pre-furnace composition analysis table of the liquid aluminum alloyThe percentage of element content is used to calculate the final required feeding amount for alloy composition adjustment, so as to more accurately determine the mass of the required feeding amount. Then, based on the calculated final required feeding amount for alloy composition adjustment , calculate according to the required feeding amount The percentage of the content of the remaining elements in the liquid aluminum alloy after adjustment, by Judge whether the value of the final required feeding amount is qualified, so as to accurately feed materials and ensure the quality of recycled aluminum alloy to the greatest extent.

[0025] Example 5 On the basis of Example 1, refining and purification includes introducing a mixed gas of nitrogen, argon, and chlorine into the aluminum melt to achieve the effect of hydrogen removal, and using any one of a foam ceramic filter, a ceramic filter, or a particle-packed bed to filter the liquid aluminum alloy to achieve the effect of impurity removal; It also includes evaluating the hydrogen removal effect within a preset time period before the end of refining and purification: Calculate the actual evaluation coefficient of hydrogen removal effect: (4); Among them, is the actual evaluation coefficient of hydrogen removal effect, is the hydrogen concentration before hydrogen removal of the liquid aluminum alloy, is the hydrogen concentration on the surface of the liquid aluminum alloy during the evaluation of hydrogen removal effect, is the average ventilation volume of the mixed gas per unit time, is the mass transfer coefficient of hydrogen in the liquid aluminum alloy, is the solubility of hydrogen in the liquid aluminum alloy, is the density of the liquid aluminum alloy, is the reference concentration of hydrogen in the liquid aluminum alloy when the hydrogen removal effect is qualified, is the average preset speed of hydrogen floating during hydrogen removal, is the hydrogen removal time; When the actual evaluation coefficient of hydrogen removal effect is greater than the preset evaluation coefficient of hydrogen removal effect, it proves that the hydrogen removal effect is qualified.

[0026] The working principle and beneficial effects of the above technical solution are as follows: The evaluation of the hydrogen removal effect is achieved by comparing the hydrogen concentrations before and after hydrogen removal. When the actual evaluation coefficient of hydrogen removal effect is greater than the preset evaluation coefficient of hydrogen removal effect, it proves that the hydrogen removal effect is qualified. Otherwise, the hydrogen removal time is increased until the actual evaluation coefficient of hydrogen removal effect is greater than the preset evaluation coefficient of hydrogen removal effect, effectively ensuring the removal of hydrogen in the purified liquid aluminum alloy, effectively avoiding the generation of pores in the recycled aluminum alloy ingot, and effectively improving the fatigue performance and mechanical properties of the recycled aluminum alloy ingot.

[0027] Example 6 On the basis of Example 1, the recycled aluminum alloy ingots after cooling and solidification are inspected, including mechanical property testing and surface quality testing, and the comprehensive mechanical property evaluation coefficient of this batch of recycled aluminum alloy ingots and the comprehensive surface quality evaluation coefficient of this batch of recycled aluminum alloy ingots are obtained respectively; The mechanical properties of this batch of recycled aluminum alloy ingots are tested using a tensile testing machine, a Brinell hardness tester, and an impact testing machine; The surface quality of this batch of recycled aluminum alloy ingots is tested using a scanner; The mechanical properties of this batch of recycled aluminum alloy ingots are tested using a tensile testing machine, a Brinell hardness tester, and an impact testing machine, and the comprehensive mechanical property evaluation coefficient of this batch of recycled aluminum alloy ingots is calculated: (5); Wherein, is the comprehensive mechanical property evaluation coefficient of this batch of recycled aluminum alloy ingots, e is a natural number with a value of 2.72, is the detection error coefficient of the tensile testing machine, is the detection error coefficient of the Brinell hardness tester, is the detection error coefficient of the impact testing machine, is the influence coefficient of the tensile property on the comprehensive mechanical properties of the recycled aluminum alloy ingots, is the detected tensile strength value of the j-th recycled aluminum alloy ingot among the sampled recycled aluminum alloy ingots in this batch, that is, the first detected value output by the tensile testing machine, is the reference tensile strength value of the recycled aluminum alloy ingots, is the detected elongation of the j-th recycled aluminum alloy ingot among the sampled recycled aluminum alloy ingots in this batch, that is, the second detected value output by the tensile testing machine, is the reference elongation of the recycled aluminum alloy ingots, n is the total number of sampled recycled aluminum alloy ingots in this batch, is the influence coefficient of the Brinell hardness property on the comprehensive mechanical properties of the recycled aluminum alloy ingots, is the detected Brinell hardness value of the j-th recycled aluminum alloy ingot among the sampled recycled aluminum alloy ingots in this batch, that is, the detected value output by the Brinell hardness tester, is the reference Brinell hardness value of the recycled aluminum alloy ingots, is the influence coefficient of the impact resistance property on the comprehensive mechanical properties of the recycled aluminum alloy ingots, is the detected impact absorption work value of the j-th recycled aluminum alloy ingot among the sampled recycled aluminum alloy ingots in this batch, that is, the detected value output by the impact testing machine, is the reference impact absorption work value of the recycled aluminum alloy ingots; When the comprehensive mechanical property evaluation coefficient of the batch of recycled aluminum alloy ingots is less than the comprehensive mechanical property benchmark evaluation coefficient of the recycled aluminum alloy ingots, it proves that the comprehensive mechanical properties of the batch of recycled aluminum alloy ingots are unqualified; The surface quality inspection of recycled aluminum alloy ingots includes: S60. Image acquisition: Use a scanner to obtain the surface image of the recycled aluminum alloy ingot; S61. Image preprocessing: Denoise, enhance the contrast and smooth the surface image of the recycled aluminum alloy ingot; S62. Image analysis system: Evaluate the pinhole degree, surface flatness, surface defects and surface coating of the recycled aluminum alloy ingot based on the preprocessed surface image of the recycled aluminum alloy ingot, and obtain the comprehensive surface quality evaluation coefficient of the batch of recycled aluminum alloy ingots .

[0028] Specifically: Pinhole degree detection: Use an image segmentation algorithm to separate the non-pinhole area of the recycled aluminum alloy ingot from the pinhole area, mark the pinhole area through feature extraction methods, and calculate the number and density of pinholes based on the marked pinhole area, so as to evaluate the pinhole degree; Surface flatness detection: Separate the surface area of the recycled aluminum alloy ingot from the background, extract the surface features, and calculate the surface flatness indexes (surface unevenness and surface roughness) of the recycled aluminum alloy ingot surface according to the extracted surface features; Surface defect detection: Separate the non-defect area of the recycled aluminum alloy ingot from the surface defect area, then use a feature extraction algorithm to extract the features of the defects, such as shape, size, texture, and use a machine learning model to classify and identify the extracted features to determine the type and location of the defects. According to the identified defects, perform quantitative analysis such as defect counting and area calculation to evaluate the surface defect situation; Surface coating detection: Separate the surface coating area of the aluminum alloy ingot from other areas, then use a feature extraction algorithm to extract the features of the coating (color and texture), evaluate the uniformity of the coating by analyzing the color or texture changes of the coating, and calculate the thickness of the coating.

[0029] (6); Among them, is the comprehensive surface quality evaluation coefficient of the batch of recycled aluminum alloy ingots, are respectively the influence coefficients of the pinhole degree, surface flatness, surface defect degree and surface coating thickness of the recycled aluminum alloy ingot on the comprehensive surface quality of the recycled aluminum alloy ingot, is the pinhole degree detection value of the recycled aluminum alloy ingot, is the pinhole degree reference value of the recycled aluminum alloy ingot, is the surface flatness detection value of the recycled aluminum alloy ingot, is the surface flatness reference value of the recycled aluminum alloy ingot, is the surface defect degree detection value of the recycled aluminum alloy ingot, is the surface defect degree reference value of the recycled aluminum alloy ingot, is the surface coating thickness detection value of the recycled aluminum alloy ingot, is the surface coating thickness reference value of the recycled aluminum alloy ingot.

[0030] The working principle and beneficial effects of the above technical solution are as follows: when detecting the mechanical properties of the recycled aluminum alloy ingot, the detected tensile strength value , the detected elongation rate , the detected Brinell hardness value and the detected impact absorption work value of the recycled aluminum alloy ingot are used. Thus, the final calculation result can more comprehensively reflect the comprehensive mechanical properties of the recycled aluminum alloy ingot. At the same time, the sampling detection method is adopted, and the values of each sampled recycled aluminum alloy ingot are used for calculation. The increase in the sampling quantity enhances the reliability of the calculation result; By detecting the pinhole degree, surface flatness, surface defects and surface coating of the recycled aluminum alloy ingot, the calculation of the comprehensive surface quality evaluation of this batch of recycled aluminum alloy ingots is realized. The surface quality of this batch of recycled aluminum alloy ingots can be reflected from the comprehensive surface quality evaluation coefficient of this batch of recycled aluminum alloy ingots, so as to realize the all-round quality acceptance of the recycled aluminum alloy ingot and ensure the ex-factory quality.

[0031] Obviously, those skilled in the art can make various changes and modifications to the present invention without departing from the spirit and scope of the present invention. Thus, if these modifications and variations of the present invention fall within the scope of the claims of the present invention and their equivalent technologies, the present invention also intends to include these changes and modifications.

Claims

1. A process for manufacturing recycled aluminum alloy ingots with precise composition control, characterized in that: The following steps are involved: S1. Collecting scrap aluminum materials, classifying and sorting the collected scrap aluminum materials to form several groups of scrap aluminum to be processed, and pre-processing the several groups of scrap aluminum to be processed to form qualified furnace materials; S2, putting the qualified furnace materials whose actual volume is larger than the preset volume into the main chamber of the melting furnace for melting, and putting the qualified furnace materials whose actual volume is smaller than the preset volume into the side chamber of the melting furnace for melting to form liquid aluminum alloy, and performing slag removal and alloy composition adjustment on the liquid aluminum alloy; S3. Dehydrogenation and impurity removal are performed on the liquid aluminum alloy after slag removal and alloy composition adjustment to remove hydrogen and solid inclusions in the liquid aluminum alloy, and the refined and purified liquid aluminum alloy is poured into a casting mold to manufacture recycled aluminum alloy ingots of a certain shape and specification, and the appearance quality of the recycled aluminum alloy ingots after cooling and solidification is inspected and removed.

2. The process for manufacturing recycled aluminum alloy ingots with precise composition control according to claim 1 is characterized in that: Pre-process several groups of scrap aluminum to be processed, including: Use crushing equipment to preliminarily disassemble and crush several groups of waste aluminum to be processed to form several groups of furnace charge blocks that are easy to process, send the several groups of furnace charge blocks to the magnetic separator respectively, remove the furnace charge blocks containing magnetic metals through the magnetic separator, put the several groups of furnace charge blocks after magnetic separation into the flotation equipment in turn, add flotation medium into the flotation equipment, adjust the density of the flotation liquid in the flotation equipment to an appropriate value, remove organic matter lighter than aluminum and other metal furnace charge blocks heavier than aluminum through the flotation equipment, clean the furnace charge blocks after flotation through high-pressure water spray cleaning equipment, recycle the washed flotation medium, and dry the cleaned furnace charge blocks through drying equipment to form qualified furnace charge.

3. The process for manufacturing recycled aluminum alloy ingots with precise composition control according to claim 1 is characterized in that: Adjusting the alloy composition of liquid aluminum alloy includes: S30, using a direct-reading spectrometer to perform a furnace composition analysis on the liquid aluminum alloy to obtain a furnace composition analysis table of the liquid aluminum alloy; S31. Calculate the final required feed amount for alloy composition adjustment based on the liquid aluminum alloy pre-furnace composition analysis table and verify it.

4. The process for manufacturing recycled aluminum alloy ingots with precise composition control according to claim 3 is characterized in that: Calculate the final required feed amount for alloy composition adjustment based on the liquid aluminum alloy pre-furnace composition analysis table and verify it, including: S310, based on the excessive content of elements in the liquid aluminum alloy pre-furnace composition analysis table The percentage of element content is used to calculate the required feed amount: （1）； in, Based on the excessive content of elements in the liquid aluminum alloy pre-furnace composition analysis table The preset required feed amount is calculated based on the percentage of element content. is the total mass of the original liquid aluminum alloy, Elements with excessive content in the liquid aluminum alloy pre-furnace composition analysis table The percentage of element content, Liquid aluminum alloy Preset qualified content percentage of elements; S311, based on the calculated preset required feeding amount And the insufficient elements in the liquid aluminum alloy pre-furnace composition analysis table The percentage of element content is used to calculate the final amount of material required to adjust the alloy composition: （2）； in, Adjust the final required feed amount for alloy composition, Liquid aluminum alloy The preset qualified content percentage of the element, The insufficient elements in the liquid aluminum alloy pre-furnace composition analysis table The percentage of element content, To supplement Elements added Element alloy The content percentage of the element.

5. The process for manufacturing recycled aluminum alloy ingots with precise composition control according to claim 4 is characterized in that: Also includes, feed quantity verification: S312, adjusting the final required feed amount based on the calculated alloy composition , calculate the required feed amount The percentage of the remaining elements in the adjusted liquid aluminum alloy: （3）； in, According to the required feed amount The percentage of the content of the i-th element in the remaining elements in the adjusted liquid aluminum alloy, is the content percentage of the i-th element in the rest of the elements in the liquid aluminum alloy pre-furnace composition analysis table, The percentage of the i-th element in the remaining elements in the aluminum material used to adjust the alloy composition; S313, if , then the verification is successful, otherwise, the final required feed amount is recalculated to adjust the alloy composition, where According to the required feed amount The preset minimum qualified content percentage of the i-th element among the remaining elements in the adjusted liquid aluminum alloy, According to the required feed amount The preset qualified maximum percentage of the ith element among the remaining elements in the adjusted liquid aluminum alloy.

6. The process for manufacturing recycled aluminum alloy ingots with precise composition control according to claim 1, characterized in that: Refining and purification includes introducing a mixed gas of nitrogen, argon and chlorine into the aluminum melt to remove hydrogen, and using any one of foam ceramic filters, ceramic filters or particle packed beds to filter the liquid aluminum alloy to remove impurities.

7. The process for manufacturing recycled aluminum alloy ingots with precise composition control according to claim 6 is characterized in that: It also includes the evaluation of hydrogen removal effect within a preset period of time before the end of refining and purification: Calculate the actual evaluation coefficient of hydrogen removal effect: （4）； in, is the actual evaluation coefficient of hydrogen removal effect, is the hydrogen concentration of the liquid aluminum alloy before dehydrogenation, is the hydrogen concentration on the surface of liquid aluminum alloy during the evaluation of dehydrogenation effect, is the average ventilation volume of the mixed gas per unit time, is the mass transfer coefficient of hydrogen in liquid aluminum alloy, is the solubility of hydrogen in liquid aluminum alloy, is the density of liquid aluminum alloy, The reference concentration of hydrogen in the liquid aluminum alloy when the dehydrogenation effect is satisfactory. is the average preset speed of hydrogen floating during the dehydrogenation process, is the hydrogen removal time; When the actual evaluation coefficient of the dehydrogenation effect is greater than the preset evaluation coefficient of the dehydrogenation effect, it is proved that the dehydrogenation effect is qualified.

8. The process for manufacturing recycled aluminum alloy ingots with precise composition control according to claim 1, characterized in that: The recycled aluminum alloy ingots after cooling and solidification are inspected, including mechanical property testing and surface quality testing, and the comprehensive mechanical property evaluation coefficients of the batch of recycled aluminum alloy ingots are obtained respectively. And the comprehensive surface quality evaluation coefficient of the batch of recycled aluminum alloy ingots ; The mechanical properties of the batch of recycled aluminum alloy ingots were tested using a tensile testing machine, a Brinell hardness tester, and an impact testing machine; A scanner is used to detect the surface quality of the batch of recycled aluminum alloy ingots.

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