Aluminum alloy round bar casting process taking oxidizing material as raw material

Abstract

The invention provides an aluminum alloy round bar casting process taking oxidized materials as raw materials, and relates to the field, the aluminum alloy round bar casting process comprises the following steps: S1, adding the oxidized materials into a smelting furnace in proportion, and smelting at the temperature of 720-760 DEG C to obtain a melt; s2, component analysis is conducted on the molten liquid, alloy elements with insufficient components are added, Ar / N mixed gas is introduced, and the molten liquid is refined; and S3, the refined melt is subjected to three-stage filtration, Al-Ti-B wires are added on line, then a rod is cast, and the cast rod is inspected, sawn and put in storage. The oxidation material is used for replacing high-price aluminum ingots, the cost of raw materials is remarkably reduced through the process, meanwhile, the product performance is kept, and the process is suitable for automobile parts and other application scenes sensitive to light weight and cost.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of aluminum alloy casting, in particular to an aluminum alloy round bar casting process using oxidized material as raw material. BACKGROUND

[0002] With the acceleration of the trend of automobile lightweight, the demand for aluminum alloy has surged, and the supply gap of upstream aluminum bar has continued to widen. However, traditional 6-series aluminum alloy production relies on high-purity aluminum ingots and primary scrap (white material), and the raw material cost accounts for more than 60% of the total production cost. In recent years, the price of aluminum ingots has fluctuated sharply (such as the average price breaking through 23,000 yuan / ton in 2023), further compressing the profit space of enterprises. In addition, due to high impurity content and unstable composition, tertiary scrap (oxidized material) is usually only used for low-end alloy production and cannot meet the purity requirements of 6-series alloys. Therefore, it is urgent to develop a new casting process using oxidized material as the core raw material to reduce the cost of raw materials while ensuring performance. SUMMARY

[0003] The purpose of the present application is to provide an aluminum alloy round bar casting process using oxidized material as raw material to solve the above technical problems.

[0004] To solve the above technical problems, the following technical solutions are adopted:

[0005] An aluminum alloy round bar casting process using oxidized material as raw material, comprising the following steps:

[0006] S1, adding oxidized material into the smelting furnace in proportion, smelting at a temperature of 720-760℃, and obtaining molten liquid;

[0007] S2, analyzing the composition of the molten liquid, adding alloying elements that are insufficient, and purging Ar / N mixed gas to refine the molten liquid;

[0008] S3, three-stage filtering of the refined molten liquid, online addition of Al-Ti-B wire, followed by casting of the bar, inspection of the cast bar, and sawing and storage.

[0009] Preferably, the oxidized material in step S1 is waste material formed after the oxidation process of aluminum profiles.

[0010] Preferably, the hydrogen content of the Ar / N mixed gas in step S2 is <0.12 mL / 100g.

[0011] Preferably, the refined molten liquid is subjected to three-stage filtering using ceramic filter plates and tubular filters in step S3.

[0012] Preferably, the Ti content of the Al-Ti-B wire in step S3 is 0.01%-0.03%.

[0013] Preferably, the crystallizer needs to be preheated to 80-150℃ before the casting rod to prevent cold start sticking aluminum;

[0014] The dummy head also needs to be raised to the bottom of the crystallizer to form a closed casting cavity;

[0015] Finally, the cooling water also needs to be debugged, and the water pressure is set to 0.2-0.5MPa, and the flow is matched with the diameter of the casting rod.

[0016] Preferably, the casting rod process includes passing the melt into the crystallizer through the flow channel, and the liquid level is controlled within ±2mm by the laser sensor; the inner wall of the crystallizer is water-cooled to make the melt surface quickly solidify to form a shell;

[0017] After the casting rod leaves the crystallizer, it is forcedly cooled by external spraying water (water temperature ≤35℃), and the dummy head is lowered at a constant speed of 50-200mm / min to maintain continuous casting.

[0018] The beneficial effects of the present application are:

[0019] The present application uses oxidized material to replace high-priced aluminum ingots, which significantly reduces the cost of raw materials while maintaining product performance, and is suitable for applications such as automobile parts that are sensitive to lightweight and cost. BRIEF DESCRIPTION OF DRAWINGS

[0020] Figure 1 is a low-power field view of an aluminum alloy round rod made of oxidized material as raw material;

[0021] Figure 2 is a low-power field view of an aluminum alloy round rod made of aluminum ingot and white material as raw material;

[0022] Figure 3 is a high-power field view of an aluminum alloy round rod made of oxidized material as raw material;

[0023] Figure 4 is a high-power field view of an aluminum alloy round rod made of aluminum ingot and white material as raw material; DETAILED DESCRIPTION

[0024] In order to facilitate the understanding of the present application, the present application will be described more fully below with reference to the related drawings. The preferred embodiments of the present application are shown in the drawings. However, the present application can be implemented in many different forms and is not limited to the embodiments described herein. On the contrary, the purpose of providing these embodiments is to make the disclosure of the present application more thorough and comprehensive.

[0025] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the present application belongs. The terms used in the specification of the present application herein are only for the purpose of describing the specific embodiments and are not intended to limit the present application.

[0026] The specific embodiments of the present application are described below with reference to the accompanying drawings.

[0027] Example 1

[0028] In this embodiment, an aluminum alloy round bar casting process using oxidized material as raw material is proposed, and the process steps are as follows:

[0029] S1, the waste material formed after the aluminum profile is subjected to the oxidation process is added into the smelting furnace in proportion (generally in the proportion of 4:3:3), and smelting is carried out at a temperature of 720-760°C to obtain a molten liquid;

[0030] S2, the composition of the molten liquid is analyzed, and alloying elements that are insufficient are added, Ar / N mixed gas (hydrogen content <0.12 mL / 100g) is introduced, and the molten liquid is refined (in this stage, the number of refining times, the length of time and the amount of refining agent used are optimized according to the different proportions of oxidized material);

[0031] S3, the molten liquid is subjected to three-stage filtration using ceramic foam (ceramic filter plate + tubular filter) to remove inclusions, and Al-Ti-B wires (Ti content 0.01%-0.03%) are added online;

[0032] S4, the crystallizer is preheated to 80-150°C to prevent aluminum sticking during cold start, the dummy bar head is raised to the bottom of the crystallizer to form a closed casting cavity, the water pressure is set to 0.2-0.5 MPa, and the flow rate is matched to the diameter of the cast bar;

[0033] S5, the melt passes through the flow channel into the crystallizer, the liquid level is controlled within ±2mm by a laser sensor, the inner wall of the crystallizer is water-cooled to rapidly solidify the melt surface to form an outer shell, after the cast bar exits the crystallizer, it is forcedly cooled by external spray water (water temperature ≤35°C), the dummy bar head is lowered at a constant speed (50-200mm / min) to maintain continuous casting, and the single casting length is usually 6-12 meters;

[0034] S6, the aluminum bar is lifted from the deep well to the material transfer platform using a trolley, then test pieces are sawn for minimum magnification inspection of the composition, the surface of the aluminum bar is visually inspected for damage such as scratches and scratches, and an ultrasonic flaw detector is used to detect whether there are cracks inside the head and tail of the aluminum bar;

[0035] S7, after the bar is inspected, the aluminum bar is subjected to homogenization treatment according to the schedule, the cooled aluminum bar is transferred to the sawing machine using a forklift or a crane, the aluminum bar is sawn into short bars of different lengths according to the required products, and then packaged and stored.

[0036] Example 2

[0037] An aluminum alloy round bar casting process using oxidized material as raw material is proposed in Example 1, and the component content of the oxidized material is adjusted to produce aluminum alloy round bars.

[0038] Comparative Example 1

[0039] Comparative Example 1 uses white material and aluminum ingot to produce aluminum alloy round bar, the process steps are as follows:

[0040] S1, the white material and aluminum ingot are added into the smelting furnace in turn, and the smelting is carried out at a temperature of 720-760℃ to obtain a molten liquid;

[0041] S2, the composition of the molten liquid is analyzed, alloying elements with insufficient composition are added, Ar / N mixed gas (hydrogen content <0.12 mL / 100g) is introduced, and the molten liquid is refined (in this stage, the number of refining, time and the amount of refining agent are optimized according to the proportion of oxidized material);

[0042] S3, two-stage filtration of the molten liquid is carried out using ceramic foam (ceramic filter plate) to remove inclusions, and Al-Ti-B wire (Ti content 0.01%-0.03%) is added online;

[0043] S4, the crystallizer is preheated to 80-150℃ to prevent cold start sticking aluminum, the dummy bar head is raised to the bottom of the crystallizer to form a closed casting cavity, the water pressure is set to 0.2-0.5 MPa, and the flow rate is matched with the diameter of the cast bar;

[0044] S5, the melt passes through the flow channel into the crystallizer, the liquid level is controlled within ±2mm by a laser sensor, the inner wall of the crystallizer is water-cooled to make the melt surface solidify quickly to form a shell, after the cast bar leaves the crystallizer, it is forcedly cooled by external spraying water (water temperature ≤35℃), the dummy bar head is lowered at a constant speed (50-200mm / min), the continuous casting is maintained, and the single casting length is usually 6-12 meters;

[0045] S6, the aluminum bar is lifted from the deep well to the material transfer platform by a trolley, then the test piece is sawn for minimum magnification inspection of composition, and whether there are scratches, scratches and other damages on the surface of the aluminum bar is observed by eye, and whether there are cracks inside the head and tail of the aluminum bar is detected by an ultrasonic flaw detector;

[0046] S7, after the bar is inspected, the aluminum bar is subjected to homogenization treatment according to the schedule, the cooled aluminum bar is transferred to the sawing machine using a forklift or a crane, the aluminum bar is sawn into short bars of different lengths according to different required products, and then packaged and stored.

[0047] Comparative Example 2

[0048] Using the aluminum alloy round bar casting process proposed in Comparative Example 1, the composition of the white material and aluminum ingot is adjusted to produce aluminum alloy round bar.

[0049] The parameters of each component in Example 1, Example 2, Comparative Example 1 and Comparative Example 2 are shown in Table 1:

[0050] Table 1: Raw material composition

[0051]

[0052] The aluminum alloy prepared in Example 1, Example 2, Comparative Example 1 and Comparative Example 2 is analyzed for composition, and the data is shown in Table 2:

[0053] Table 2: Composition of aluminum alloy

[0054] Example 1 Example 2 Comparative Example 1 Comparative Example 2 Si % 0.494 0.493 0.479 0.492 Fe % 0.138 0.129 0.126 0.128 Cu % 0.0064 0.0038 0.0026 0.0077 Mn % 0.0154 0.0092 0.0090 0.0505 Mg % 0.564 0.555 0.567 0.558 Zn % 0.0072 0.0090 0.0143 0.0290 Cr％ 0.0034 0.0024 0.0023 0.0089 Ti % 0.0185 0.0183 0.0180 0.0183 Al％ 98.64 98.70 98.68 98.63

[0055] Referring to Figures 1-4 (Aluminum alloy shown in Figure 1 and Figure 2 Table 2, the aluminum alloy prepared in Example 1 and the aluminum alloy prepared in Comparative Example 1 are not much different in purity, and the aluminum alloy prepared in Comparative Example 1 is slightly higher, but the raw material used in Example 1 is waste material, so the cost can be effectively saved.

[0056] The present application innovatively uses three-stage waste material (oxidized material) as the main raw material, and through optimization of component ratio and process flow, the purity of the final product is ensured to be comparable to that of the traditional process (aluminum ingot + white material).

[0057] The process flow covers key steps such as melting (precise temperature control at 720-760℃), refining (Ar / N2 mixed gas to remove hydrogen), filtration (two-stage ceramic foam filtration), grain refinement (online addition of Al-Ti-B wire), and detailed specifications of casting preparation (mold preheating, cooling water debugging), continuous casting (liquid level control, secondary cooling), quality inspection (ultrasonic flaw detection, high-power microscopic analysis) and emergency treatment measures (melt leakage alarm, standby cooling system). By using oxidized material to replace high-priced aluminum ingot, this process significantly reduces the cost of raw materials while maintaining product performance, and is suitable for automotive parts and other applications sensitive to lightweight and cost. In addition, comparative data of purity of new and old processes are provided to verify the technical feasibility, and an economic and efficient solution is provided for the aluminum processing industry.

[0058] The technical features of the above-described embodiments can be combined in any manner. To make the description concise, not all possible combinations of the technical features in the above-described embodiments are described, however, as long as the combinations of the technical features do not contradict, they should be considered within the scope of the present disclosure.

[0059] The above embodiments only express several implementation manners of the present application, and the description is more specific and detailed, but it should not be understood as a limitation on the scope of the patent. It should be noted that for ordinary skilled persons in the art, without departing from the concept of the present application, several modifications and improvements can be made, which are within the scope of protection of the present application. Therefore, the protection scope of the patent of the present application should be subject to the appended claims.

Claims

1. A casting process for aluminum alloy round bars using anodized materials as raw materials, characterized in that, It comprises the following steps: S1. Oxidized materials are added into a smelting furnace in proportion, smelting is carried out at a temperature of 720-760℃, and a molten liquid is obtained; S2. The molten liquid is analyzed for its composition, alloy elements that are insufficient are added, Ar / N mixed gas is introduced, and the molten liquid is refined; S3. The refined molten liquid is filtered in three stages, Al-Ti-B wires are added in line, and then a cast bar is obtained, the cast bar is inspected, and is sawed and stored.

2. The aluminum alloy round bar casting process using oxidized material as a raw material according to claim 1, characterized in that: The oxidized materials in step S1 are waste materials formed after aluminum profiles are oxidized.

3. The aluminum alloy round bar melting and casting process using oxidized material as raw material according to claim 1, characterized in that: The hydrogen content of the Ar / N mixed gas in step S2 is <0.12 mL / 100g.

4. The aluminum alloy round bar melting and casting process using oxidized material as raw material according to claim 1, characterized in that: The refined molten liquid is filtered in three stages using ceramic filter plates and a tubular filter in step S3.

5. The aluminum alloy round bar melting and casting process using oxidized material as raw material according to claim 1, characterized in that: The Ti content of the Al-Ti-B wires in step S3 is 0.01%-0.03%.

6. The aluminum alloy round bar melting and casting process using oxidized material as raw material according to claim 1, characterized in that: The crystallizer needs to be preheated to 80-150℃ before the cast bar is obtained to prevent sticking of aluminum due to cold start, the dummy head also needs to be raised to the bottom of the crystallizer to form a closed casting cavity, and finally the cooling water needs to be adjusted, with the water pressure set to 0.2-0.5 MPa and the flow rate matched to the diameter of the cast bar.

7. The process according to claim 1, wherein the process is characterized by: The cast bar process comprises passing the melt into the crystallizer through a flow channel, the liquid level is controlled within ±2mm by a laser sensor, the inner wall of the crystallizer is water-cooled to rapidly solidify the surface of the melt to form a shell, after the cast bar exits the crystallizer, external spray water is used for forced cooling, and the dummy head is lowered at a constant speed to maintain continuous casting.

8. The aluminum alloy round bar melting and casting process using oxidized material as raw material according to claim 7, characterized in that: The water temperature of the external spray water is ≤35℃.

9. The process according to claim 7, wherein the process is characterized by: The dummy head is lowered at a constant speed of 50-200 mm / min.

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