Solvent-free aluminum alloy casting process

Abstract

The invention discloses a solvent-free aluminum alloy casting process, and particularly relates to the technical field of casting processes, the casting process relates to a smelting device and a pouring device.The smelting device comprises a furnace body, an induction coil is fixedly arranged on the inner wall of the furnace body, a crucible used for containing raw materials is arranged in the furnace body, and the crucible is located on the inner side of the induction coil; a grid plate is arranged on the inner wall of the crucible, leakage holes are formed in the bottom end of the crucible, an annular supporting frame is fixedly arranged at the bottom end in the furnace body, the crucible is erected at the top end of the annular supporting frame, a notch is formed in the front side of the annular supporting frame, and an outflow assembly is arranged at the bottom of the crucible and comprises a flow guide channel. A large number of raw materials are added into the crucible at a time, the raw materials which are melted firstly are collected and discharged for casting work while heating is conducted, the raw materials do not need to be completely melted, the time for waiting for melting and frequently adding the raw materials is saved, and the melting efficiency is greatly improved.

Description

Technical Field

[0001] The present invention relates to the technical field of casting processes, and particularly to a solvent-free aluminum alloy casting process. Background Art

[0002] The aluminum alloy casting process is to heat and melt aluminum alloy materials at high temperatures, and then inject the melted aluminum alloy materials into molds to cast corresponding workpieces, such as the energy-saving and efficient aluminum alloy casting process disclosed in the prior art with the publication number CN103614579A.

[0003] Since aluminum alloy workpieces are widely used in many fields such as automobile manufacturing, aerospace, and construction, their casting processes are also very commonly used.

[0004] Traditional aluminum alloy casting processes generally use the combustion of coal and gas to heat raw materials when melting them. In recent years, this method has been replaced by electric heating, which is more efficient and environmentally friendly.

[0005] When heating and melting raw materials, the materials are generally added to the melting furnace at one time. After they are completely melted from solid to liquid, they are taken out for casting. However, it takes a relatively long time for the raw materials to be completely melted, which affects the efficiency of the entire process flow and makes the efficiency to be improved. Summary of the Invention

[0006] The purpose of the present invention is to provide a solvent-free aluminum alloy casting process. By collecting and discharging the first-melted raw materials for casting work while heating, it is not necessary to wait for the raw materials to be completely melted, saving the time for waiting for melting and frequently adding raw materials, and greatly improving the melting efficiency.

[0007] To achieve the above purpose, the present invention provides the following technical solution: A solvent-free aluminum alloy casting process, and the specific steps are as follows:

[0008] Step 1: Prepare raw materials, clean the dirt on the surface of the raw materials to avoid impurities in the melted aluminum, and cut large solid raw materials into small pieces. The overall length of the raw materials shall not exceed 1 m to improve the heating efficiency and shorten the melting time;

[0009] Step 2: Put the prepared raw materials into the smelting device, then close the smelting device, energize the smelting device, and heat the raw materials using the principle of electromagnetic induction;

[0010] Step 3: During the smelting process, molten metal is continuously discharged from the smelting device. Use a high-temperature-resistant container to continuously receive the discharged molten metal. The molten metal that the container can hold is sufficient to cast an aluminum alloy workpiece;

[0011] Step 4: Install the pouring device at the pouring port of the mold, then pour the molten metal in the container into the pouring device, and inject the molten metal into the mold with the help of the pouring device. The pouring device can prevent the molten metal from splashing;

[0012] Step 5: After pouring is completed, wait for the molten metal to cool and solidify again to form an aluminum alloy workpiece, and take out the solidified aluminum alloy workpiece in the mold to complete the casting.

[0013] Further, the melting device in Steps 2 and 3 includes a furnace body. An induction coil is fixedly arranged on the inner wall of the furnace body. A crucible for placing raw materials is arranged inside the furnace body, and the crucible is located inside the induction coil;

[0014] When alternating current passes through the induction coil, an alternating magnetic field will be generated. This magnetic field will induce eddy currents in the raw materials. When the eddy currents flow inside the raw materials, heat will be generated, thereby heating the raw materials.

[0015] A grid plate is arranged on the inner wall of the crucible. The inner diameter of each grid on the grid plate is less than 1 cm. A leakage hole is opened at the bottom end of the crucible. Due to the skin effect, high-frequency alternating current will cause the current to be mainly concentrated on the surface of the raw materials, resulting in a rapid increase in the surface temperature, while the internal temperature rises slowly. Therefore, the surface of the raw materials melts first, and the melted liquid drips downward and passes through the grid plate, and finally flows out of the crucible through the leakage hole.

[0016] Further, an annular support frame is fixedly arranged at the bottom end inside the furnace body. The crucible is placed on the top end of the annular support frame, and a notch is opened at the front side of the annular support frame.

[0017] Further, an outflow assembly is arranged at the bottom of the crucible. The outflow assembly includes a diversion channel. The rear end of the diversion channel extends into the inside of the annular support frame through the notch and is fixedly provided with a receiving hopper. The receiving hopper is arranged at the top end of the diversion channel and is located directly below the leakage hole;

[0018] An extension opening is opened at the front side of the furnace body. The front end of the diversion channel extends to the front side of the furnace body through the extension opening and is provided with a drainage groove. The diversion channel is rotatably connected to the inner wall of the extension opening. The diversion channel forms a lever that can rotate and tilt back and forth. A hydraulic cylinder is hinged at the top end of the diversion channel, and the top end of the hydraulic cylinder is hinged to the front side of the furnace body. The angle and direction of the tilt of the diversion channel are controlled by the telescopic movement of the hydraulic cylinder.

[0019] Further, a furnace cover is arranged at the top end of the furnace body. A vibration assembly is arranged on the furnace cover. An extension piece is fixedly arranged at the top end of the crucible. When the furnace cover covers the top end of the furnace body, the top end of the extension piece can be connected to the vibration assembly;

[0020] The vibration assembly includes elastic fixing blocks embedded in the furnace cover. The elastic fixing blocks are made of fluororubber and can withstand high temperatures of 200°C. A fixing core is fixedly arranged on the elastic fixing blocks. An installation platform is fixedly arranged at the top end of the fixing core. A vibration motor is installed at the top end of the installation platform. A connecting plate is fixedly arranged at the bottom end of the fixing core. A clamping plate is fixedly arranged at the bottom end of the connecting plate. The extension piece can be inserted into the interior of the clamping plate.

[0021] Furthermore, a column is provided at the rear side of the furnace body. A linear motor is fixedly arranged on the front side of the column. A fixing beam is arranged on the mover of the linear motor. The front end of the fixing beam is connected to the top end of the furnace cover by bolts.

[0022] Furthermore, the pouring device in step four includes a pouring hopper. A plug tube is fixedly arranged at the bottom end of the pouring hopper. The plug tube can be inserted into the pouring port of the mold. A conical cover is arranged inside the pouring hopper. A plurality of connecting rods connected to the inner wall of the pouring hopper are fixedly arranged at the outer end of the conical cover.

[0023] In the above technical solution, the technical effects and advantages provided by the present invention are as follows:

[0024] 1. By adding a large amount of raw materials into the crucible at one time, while heating, collecting and discharging the first melted raw materials for casting work, without waiting for the raw materials to be completely melted, saving the time of waiting for melting and frequently adding raw materials, and greatly improving the melting efficiency;

[0025] 2. Connect the pouring hopper and the plug tube to the pouring port of the mold, and arrange a conical cover inside the pouring hopper. The conical cover can block the molten metal splashed due to the gushing of air during the pouring process, avoiding the molten metal splashing and causing injury to personnel, and improving the safety during the pouring process. Description of the Drawings

[0026] In order to more clearly illustrate the technical solutions in the embodiments of the present application or the prior art, the following will briefly introduce the drawings required to be used in the embodiments. Obviously, the drawings described below are only some embodiments recorded in the present invention. For those of ordinary skill in the art, other drawings can also be obtained according to these drawings.

[0027] Figure 1 It is a structural diagram of the smelting device;

[0028] Figure 2 It is an internal structural diagram of the furnace body of the smelting device;

[0029] Figure 3 It is for Figure 2 The enlarged view of part A in

[0030] Figure 4 It is an exploded view of the crucible, annular support frame and grid plate of the smelting device;

[0031] Figure 5 Cross-sectional view of the furnace cover of the smelting device;

[0032] Figure 6 Structural diagram of the external flow component of the smelting device;

[0033] Figure 7 Structural diagram of the pouring device;

[0034] Figure 8 Internal structural diagram of the pouring hopper of the pouring device.

[0035] Explanation of reference numerals:

[0036] 1. Furnace body; 2. Hydraulic cylinder; 3. External flow component; 301. Diversion channel; 302. Drainage tank; 303. Receiving hopper; 4. Furnace cover; 5. Vibration component; 501. Vibration motor; 502. Elastic fixing block; 503. Fixed core; 504. Installation platform; 505. Connecting plate; 506. Clamping plate; 6. Linear motor; 7. Fixed beam; 8. Column; 9. Crucible; 10. Induction coil; 11. Ring-shaped support frame; 12. Leak hole; 13. Extension piece; 14. Grid plate; 15. Notch;

[0037] 16. Pouring hopper; 17. Conical cover; 18. Insertion tube; 19. Connecting rod. Detailed implementation manners

[0038] In order to enable those skilled in the art to better understand the technical solution of the present invention, the present invention will be further introduced in detail below with reference to the accompanying drawings.

[0039] The present invention provides a solvent-free aluminum alloy melting and casting process as shown in Figures 1-5 The specific steps are as follows:

[0040] Step 1: Prepare raw materials, clean the dirt on the surface of the raw materials to avoid impurities in the molten aluminum after melting, and cut large solid raw materials into small pieces. The overall length of the raw materials shall not exceed 1 m to improve the heating efficiency and shorten the melting time;

[0041] Step 2: Put the prepared raw materials into the smelting device, then close the smelting device, energize the smelting device, and heat the raw materials by using the principle of electromagnetic induction;

[0042] Step 3: During the smelting process, molten metal is continuously discharged from the smelting device, and a high-temperature-resistant container is used to continuously receive the discharged molten metal. The molten metal that the container can hold is sufficient to cast an aluminum alloy workpiece;

[0043] Step 4: Install the pouring device at the pouring port of the mold, then pour the molten metal in the container into the pouring device, and inject the molten metal into the mold with the help of the pouring device. The pouring device can prevent the molten metal from splashing;

[0044] Step Five: After the pouring is completed, wait for the molten metal to cool and solidify again to form an aluminum alloy workpiece, and take out the solidified aluminum alloy workpiece in the mold to complete the casting.

[0045] Such as Figures 1-6 shown, the smelting device involved in Steps Two and Three includes a furnace body 1, an induction coil 10 is fixedly arranged on the inner wall of the furnace body 1, a crucible 9 for placing raw materials is arranged inside the furnace body 1, and the crucible 9 is located inside the induction coil 10;

[0046] A grid plate 14 is arranged on the inner wall of the crucible 9, the inner diameter of each grid on the grid plate 14 is less than 1 cm, and a leakage hole 12 is opened at the bottom end of the crucible 9.

[0047] A ring-shaped support frame 11 is fixedly arranged at the bottom end inside the furnace body 1, the crucible 9 is placed on the top end of the ring-shaped support frame 11, and a notch 15 is opened at the front side of the ring-shaped support frame 11.

[0048] Place the raw materials to be processed inside the crucible 9. The solid raw materials are located on the top end of the grid plate 14 inside the crucible 9. Then, energize the induction coil 10. When alternating current passes through the induction coil 10, an alternating magnetic field will be generated. This magnetic field will induce eddy currents in the raw materials. When the eddy currents flow inside the raw materials, heat will be generated, thereby heating the raw materials. During the heating process, due to the skin effect, high-frequency alternating current will cause the current to be mainly concentrated on the surface of the raw materials, resulting in a rapid increase in the surface temperature, while the internal temperature rises relatively slowly. Therefore, the surface of the raw materials melts first. The melted liquid drips downward and passes through the grid plate 14, and the unmelted part still remains on the top end of the grid plate 14. The molten metal flows to the leakage hole 12 after passing through the grid plate 14 and finally flows out of the crucible 9 through the leakage hole 12.

[0049] After the melted molten metal is discharged, it can be used. Such as Figure 1 、 2 、4, 6 shown, an outflow assembly 3 is arranged at the bottom of the crucible 9. The outflow assembly 3 includes a diversion channel 301. The rear end of the diversion channel 301 extends into the inside of the ring-shaped support frame 11 through the notch 15 and is fixedly provided with a material receiving hopper 303. The material receiving hopper 303 is arranged at the top end of the diversion channel 301 and is located directly below the leakage hole 12;

[0050] An extension port is opened at the front side of the furnace body 1. The front end of the diversion channel 301 extends to the front side of the furnace body 1 through the extension port and is provided with a liquid discharge groove 302. The diversion channel 301 is rotatably connected to the inner wall of the extension port. The diversion channel 301 forms a lever that can rotate and tilt back and forth. A hydraulic cylinder 2 is hinged to the top end of the diversion channel 301, and the top end of the hydraulic cylinder 2 is hinged to the front side of the furnace body 1. The angle and direction of the tilt of the diversion channel 301 are controlled by the telescopic movement of the hydraulic cylinder 2.

[0051] The molten metal dripping downward through the leakage hole 12 falls into the material receiving hopper 303 and finally accumulates inside the diversion channel 301. At the beginning, the whole diversion channel 301 is inclined backward, with the rear end of the diversion channel 301 at a lower position and the front end at a higher position, so the molten metal will not flow out. During casting, the front end of the diversion channel 301 is pushed downward by the hydraulic cylinder 2, the whole diversion channel 301 rotates and tilts forward. When the front end position of the diversion channel 301 is lower than the rear end, the molten metal accumulated in the diversion channel 301 will flow forward along the diversion channel 301 and flow out through the liquid discharge groove 302 into the container. By this way, a large amount of raw materials can be added at one time without waiting for them to be completely melted. Once the raw materials are melted, they are collected for casting, saving the time of waiting for melting and frequently adding raw materials, and greatly improving the melting efficiency.

[0052] During the smelting process, the opening of the furnace body 1 needs to be closed. As shown in FIGS. Figure 1 、 5 The top of the furnace body 1 is provided with a furnace cover 4, and the furnace cover 4 is provided with a vibration assembly 5. The top of the crucible 9 is fixedly provided with an extension piece 13. When the furnace cover 4 covers the top of the furnace body 1, the top of the extension piece 13 can be connected to the vibration assembly 5;

[0053] A column 8 is provided at the rear side of the furnace body 1, a linear motor 6 is fixedly provided on the front side of the column 8, a fixed beam 7 is provided on the mover of the linear motor 6, and the front end of the fixed beam 7 is connected to the top of the furnace cover 4 by bolts.

[0054] During the smelting process, the furnace cover 4 covers the top of the furnace body 1. When the opening at the top of the furnace body 1 needs to be opened, the mover of the linear motor 6 moves vertically to drive the fixed beam 7, and the fixed beam 7 drives the furnace cover 4 to move upward, so the opening at the top of the furnace body 1 can be opened. On the contrary, when the mover of the linear motor 6 moves downward, it can drive the furnace cover 4 to close the top of the furnace body 1.

[0055] The liquid formed after the metal is melted is relatively viscous and has strong adhesion. To promote its flow, as shown in FIGS. Figure 1 、 4 、5, the vibration assembly 5 includes an elastic fixing block 502 embedded in the furnace cover 4. The elastic fixing block 502 is made of fluororubber and can withstand a high temperature of 200 °C. A fixing core 503 is fixedly provided on the elastic fixing block 502, an installation table 504 is fixedly provided at the top of the fixing core 503, a vibration motor 501 is installed at the top of the installation table 504, a connecting plate 505 is fixedly provided at the bottom of the fixing core 503, a clamping plate 506 is fixedly provided at the bottom of the connecting plate 505, and the extension piece 13 can be inserted into the inside of the clamping plate 506.

[0056] While the furnace lid 4 covers the top end of the furnace body 1, the extension piece 13 at the top end of the crucible 9 is aligned with the clamping plate 506 and inserted therein. In this way, during the subsequent heating process, when the vibration motor 501 is turned on, the mounting table 504, the fixed core 503, the connecting plate 505 and the clamping plate 506 are driven to vibrate by the vibration motor 501. The vibration will affect the extension piece 13, thereby driving the crucible 9 to vibrate. Moreover, the aluminum alloy raw materials during the heating and melting process inside the crucible 9 will also vibrate accordingly. The vibration causes the first-melted part on the surface of the raw materials to quickly drip, and the molten metal adhering to the grid plate 14 and the inner wall of the crucible 9 also quickly drips, promoting the flow of the molten metal and improving the efficiency of molten metal collection.

[0057] The molten metal after melting needs to be injected into a mold. As Figure 7 , 8 shown, the pouring device involved in step four includes a pouring hopper 16. A plug tube 18 is fixedly provided at the bottom end of the pouring hopper 16. The plug tube 18 can be inserted into the pouring port of the mold. A conical cover 17 is provided inside the pouring hopper 16. A plurality of connecting rods 19 connected to the inner wall of the pouring hopper 16 are fixedly provided at the outer end of the conical cover 17.

[0058] Before injecting the molten metal, first insert the plug tube 18 into the pouring port of the mold, and then pour the molten metal scooped out from the container into the pouring hopper 16. After the molten metal enters the pouring hopper 16, it lands on the top end of the conical cover 17 and flows downward along the inclined upper surface of the conical cover 17, and continues to flow downward through the gap between the conical cover 17 and the inner wall of the pouring hopper 16, and finally is injected into the mold through the plug tube 18. During the injection process, the molten metal may temporarily accumulate at the plug tube 18. At the same time, air may gush out of the mold due to high temperature, and the gushing air will impact the accumulated molten metal and cause it to splash. However, the conical cover 17 is provided directly above the plug tube 18, and the conical cover 17 plays a role in blocking, preventing the molten metal from splashing and causing injury to personnel, and improving the safety during the pouring process.

[0059] Only some exemplary embodiments of the present invention have been described by way of illustration above. Undoubtedly, for those of ordinary skill in the art, without departing from the spirit and scope of the present invention, the described embodiments can be modified in various different ways. Therefore, the above drawings and descriptions are illustrative in nature and should not be construed as limiting the protection scope of the claims of the present invention.

Claims

1. A solvent-free aluminum alloy melting and casting process, characterized in that: The specific steps are as follows: Step 1: Prepare the raw materials, clean the dirt on the surface of the raw materials, and cut the large solid raw materials into small pieces. The overall length of the raw materials shall not exceed 1 m. Step 2: Put the prepared raw materials into the melting device, then close the melting device, power on the melting device, and heat the raw materials. Step 3: During the melting process, molten metal is continuously discharged from the melting device. Use a container to continuously receive the discharged molten metal. Step 4: Install the pouring device at the pouring port of the mold, then pour the molten metal in the container into the pouring device, and inject the molten metal into the mold with the help of the pouring device. Step 5: After pouring is completed, wait for the molten metal to cool and solidify again to form an aluminum alloy workpiece, and take out the solidified aluminum alloy workpiece in the mold to complete the melting and casting.

2. The solvent-free aluminum alloy melting and casting process according to claim 1, characterized in that: The melting device in Steps 2 and 3 includes a furnace body (1). An induction coil (10) is fixedly arranged on the inner wall of the furnace body (1). A crucible (9) for placing raw materials is arranged inside the furnace body (1), and the crucible (9) is located inside the induction coil (10). A grid plate (14) is arranged on the inner wall of the crucible (9), and a leakage hole (12) is opened at the bottom end of the crucible (9).

3. A solvent-free aluminum alloy melting and casting process according to claim 2, characterized in that: An annular support frame (11) is fixedly arranged at the bottom end inside the furnace body (1). The crucible (9) is placed on the top end of the annular support frame (11), and a notch (15) is opened at the front side of the annular support frame (11).

4. A solvent-free aluminum alloy melting and casting process according to claim 3, characterized in that: An outflow assembly (3) is arranged at the bottom of the crucible (9). The outflow assembly (3) includes a diversion channel (301). The rear end of the diversion channel (301) extends into the annular support frame (11) through the notch (15) and is fixedly provided with a receiving hopper (303). An extension port is opened at the front side of the furnace body (1). The front end of the diversion channel (301) extends to the front side of the furnace body (1) through the extension port and is provided with a liquid discharge groove (302). The diversion channel (301) is rotationally connected to the inner wall of the extension port. A hydraulic cylinder (2) is hinged to the top end of the diversion channel (301), and the top end of the hydraulic cylinder (2) is hinged to the front side of the furnace body (1).

5. A solvent-free aluminum alloy melting and casting process according to claim 2, characterized in that: A furnace cover (4) is arranged at the top end of the furnace body (1). A vibration assembly (5) is arranged on the furnace cover (4). An extension piece (13) is fixedly arranged at the top end of the crucible (9), and the top end of the extension piece (13) can be connected to the vibration assembly (5). The vibration assembly (5) includes an elastic fixing block (502) embedded in the furnace cover (4). A fixing core (503) is fixedly arranged on the elastic fixing block (502). An installation table (504) is fixedly arranged at the top end of the fixing core (503). A vibration motor (501) is installed at the top end of the installation table (504). A connecting plate (505) is fixedly arranged at the bottom end of the fixing core (503). A clamping plate (506) is fixedly arranged at the bottom end of the connecting plate (505), and the extension piece (13) can be inserted into the inside of the clamping plate (506).

6. The solvent-free aluminum alloy melting and casting process according to claim 5, characterized in that: A column (8) is arranged at the rear side of the furnace body (1). A linear motor (6) is fixedly arranged on the front side of the column (8). A fixing beam (7) is arranged on the mover of the linear motor (6), and the front end of the fixing beam (7) is connected to the top end of the furnace cover (4).

7. A solvent-free aluminum alloy melting and casting process according to claim 1, characterized in that: The perfusion device in Step 4 includes a perfusion hopper (16). A cannula (18) is fixedly provided at the bottom end of the perfusion hopper (16). A conical cover (17) is arranged inside the perfusion hopper (16). A plurality of connecting rods (19) which are connected to the inner wall of the perfusion hopper (16) are fixedly provided at the outer end of the conical cover (17).

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