Aluminum alloy melting and casting refining homogenization device

Abstract

The application relates to the technical field of aluminum alloy product manufacturing, in particular to an aluminum alloy melting and casting refining and homogenizing device, which comprises a driving mechanism, a stirring shaft, stirring blades and a tank body, the stirring shaft is driven to rotate by the driving mechanism and extends into the tank body, the stirring blades are arranged on the stirring shaft, the stirring shaft is a hollow structure, a flow channel is formed in the stirring shaft, and a cyclone blade is fixedly arranged in the stirring shaft; at least one jet hole in communication with the flow channel is arranged on the side wall of the stirring shaft. The application breaks the flow field limitation of traditional stirring and realizes active and forced homogenization in the whole molten pool range.

Description

Technical Field

[0001] This application relates to the technical field of aluminum alloy product manufacturing, and in particular to an aluminum alloy melting, casting, refining and homogenizing device. Background Technology

[0002] In the casting process of aluminum alloys, to ensure the mechanical properties, corrosion resistance, and machinability of the final product, the melt must undergo thorough refining and homogenization before casting. The purpose of homogenization is to ensure that the alloy composition and temperature in different regions of the molten pool are uniform through vigorous stirring, and to promote sufficient contact between refining gases and the melt to remove hydrogen and inclusions. Incomplete homogenization can lead to defects such as component segregation, shrinkage cavities, and inclusions in the ingot, severely affecting product quality.

[0003] Currently, most common homogenization devices employ mechanical stirring. Their main structure includes a drive motor, a stirring shaft extending into the melt, and stirring blades fixed to the lower part of the shaft. The drive motor rotates the stirring shaft, and the blades agitate the melt, creating eddies and achieving a certain degree of mixing. These devices are relatively simple in structure and have low manufacturing costs, making them widely used basic homogenization equipment in industrial production.

[0004] However, existing mechanical stirring devices have significant drawbacks. First, their stirring action is mainly concentrated in the area near the blades. In the upper part of the molten pool, especially in the corner areas far from the blades, the melt flow is poor, easily forming "dead zones" and leading to uneven composition and temperature. Second, traditional stirring methods have a relatively unidirectional convection direction. For denser alloying elements or inclusions deposited at the bottom of the molten pool, it is difficult to effectively pick them up and evenly disperse them throughout the melt, easily causing uneven mixing and deposition. In addition, violent surface vortices can draw in air, causing secondary oxidation of the aluminum melt and creating new inclusions. Utility Model Content

[0005] This application provides an aluminum alloy melting, casting, refining, and homogenization apparatus, which at least partially solves the above-mentioned technical problems.

[0006] This application provides an aluminum alloy melting, casting, refining, and homogenization apparatus, which adopts the following technical solution: An aluminum alloy melting, casting, refining, and homogenization device includes a drive mechanism, a stirring shaft, stirring blades, and a tank. The stirring shaft is driven to rotate by the drive mechanism and extends into the tank. The stirring blades are disposed on the stirring shaft. The stirring shaft has a hollow structure, forming a flow channel, and swirling blades are fixedly disposed inside it. At least one jet hole communicating with the flow channel is opened on the side wall of the stirring shaft.

[0007] By adopting the above technical solution, the drive mechanism drives the hollow stirring shaft to rotate, and the stirring blades fixed on it perform basic stirring; at the same time, the rotating stirring shaft drives the internal swirling blades to rotate at high speed. The rotation of the swirling blades generates centrifugal force in the aluminum liquid in the flow channel, forming a low-pressure zone, thereby "negatively sucking" the aluminum liquid at the bottom and around the stirring shaft into the flow channel and conveying it upward; the lifted aluminum liquid is finally ejected at high speed from the jet holes on the side wall of the stirring shaft under the action of centrifugal pressure; this reduces the "stirring dead zone" problem mentioned in the background technology, especially for mixing in the upper layer of the molten pool; the ejected aluminum liquid jet can effectively impact areas outside the direct action range of the stirring blades, breaking the flow field limitations of traditional stirring and realizing active and forced homogenization throughout the entire molten pool; at the same time, the process of sucking in aluminum liquid from the bottom also helps to re-roll up any components that may be deposited to participate in the circulation.

[0008] Optionally, an annular shielding tube is fixedly provided on the inner wall of the tank. Vertical shielding areas and blank areas are alternately arranged on the tube wall. The shielding tube is located outside the stirring shaft. The shielding areas and blank areas intersect and pass through part of the spray holes.

[0009] By adopting the above technical solution, when molten aluminum is ejected at high speed from the nozzle, it directly impacts the annular baffle tube fixed on the inner wall of the tank. Because the baffle tube alternately has baffle and blank areas, the molten aluminum jet encounters two different situations: in the baffle area, the jet is blocked and broken, its energy dissipated and transformed into finer turbulence; in the blank area, the jet can pass through more smoothly and reach a more distant area of ​​the tank wall. The design of the baffle tube cleverly solves the problem of secondary oxidation caused by "intense surface vortices entraining air." It effectively suppresses the overall large vortex caused by a high-speed jet in a single direction. Simultaneously, through a "partial baffle, partial release" approach, it reconstructs a concentrated high-energy jet into multi-layered turbulences with varying directions and intensities, greatly enhancing the mixing efficiency at the microscopic level of the melt and making the homogenization of composition and temperature more thorough.

[0010] Optionally, the jet holes are non-uniformly distributed along the axial and circumferential directions on the sidewall of the stirring shaft.

[0011] By adopting the above technical solution, due to the non-uniform distribution of the jet holes in the axial and circumferential directions, the aluminum liquid will be ejected from different heights and angles when the stirring shaft rotates, forming a dynamic and three-dimensional jet network. This non-uniform distribution ensures that the aluminum liquid jet can cover every corner of the molten pool without dead angles. It avoids the new "mixing dead zone" that may be generated due to the regular distribution of jet holes, so that every part of the melt from the top to the bottom of the tank and from the center to the edge can be periodically flushed and mixed by the high-speed jet.

[0012] Optionally, the inner wall of the stirring shaft is coated with a high-temperature resistant non-stick coating.

[0013] By adopting the above technical solution, before and after the device is running or at any time when it is stopped, the aluminum liquid is difficult to adhere to the inner wall of the stirring shaft due to the high temperature resistant non-stick coating. This directly solves the potential risk that the aluminum liquid will easily cool and solidify in the internal flow channel and block the flow channel. It ensures the long-term smooth flow of the internal circulation channel, so that the homogenization effect can be maintained, and the device can operate stably and reliably. This greatly improves the practicality and service life of the device and reduces maintenance costs.

[0014] Optionally, the jet orifice is a conical orifice, the diameter of which gradually increases from the inside of the flow channel toward the inside of the tank.

[0015] By employing the above technical solution, the molten aluminum is pressurized within the flow channel and ejected from the conical jet orifice. As the orifice diameter gradually increases, some of the fluid's pressure energy is converted into velocity energy, resulting in a higher and more concentrated jet velocity. The conical orifice design utilizes fluid dynamics principles to enhance the jet's exit velocity and kinetic energy. This means the jet can penetrate greater distances and has stronger entrainment and stirring capabilities, thereby enhancing the homogenization intensity and effective range of the jet orifice.

[0016] Optionally, it further includes an annular outer cylinder, which is sleeved outside the stirring shaft by an adjustment component and located between the stirring shaft and the shielding tube; the outer cylinder wall is provided with an adjustment hole adapted to the jet hole; by driving the outer cylinder to move or rotate relative to the stirring shaft by the adjustment component, the overlap between the adjustment hole and the jet hole can be changed, thereby adjusting the size and position of the jet opening.

[0017] By adopting the above technical solution, the operator can drive the outer cylinder to move or rotate relative to the stirring shaft by adjusting the components. When the adjusting hole and the jet hole are completely aligned, the jet flows smoothly; when they are partially aligned, the jet is partially blocked and the jet becomes thinner; when they are completely misaligned, the jet at that point is completely blocked. This provides a real-time, adjustable two-stage flow distribution system, which allows the operator to flexibly adjust the jet intensity in different height areas, or even shut down the jet in a certain area, according to the specific alloy formula, melt temperature, or process stage. The blocking tube is responsible for macroscopic flow field reconstruction, while the adjustable outer cylinder is responsible for precise microscopic flow control. The combination of the two achieves refined and customized management of the homogenization process.

[0018] Optionally, the adjusting assembly includes a fixing block, a fixing ring, and a locking bolt. The fixing block is located at one end of the stirring shaft near the bottom of the tank, and multiple fixing blocks are arranged along the circumference of the stirring shaft. The fixing ring is rotatably mounted on the stirring shaft and has a snap-fit ​​groove that snaps into the fixing block. The locking bolt is located on the outer cylinder and is threadedly connected to the stirring shaft.

[0019] By adopting the above technical solution, when it is necessary to adjust the position between the outer cylinder and the jet hole, the fixing ring is rotated so that the locking groove engages with different fixing blocks, so that the jet hole is connected to or closed with different adjustment holes, thereby realizing the adjustment of the jet position. Then, it is fixed with locking bolts. The adjustment component has a simple structure, is easy to operate, and has high stability.

[0020] Optionally, the outer cylinder is provided with a disturbance blade, and the disturbance blade is set at an angle to the stirring blade.

[0021] By adopting the above technical solution, when the stirring shaft rotates, it drives the outer cylinder and the disturbance blades on it to rotate together. These disturbance blades are at an angle to the main stirring blades, so the direction of the flow field they generate is different from that of the main stirring blades. The introduction of disturbance blades increases additional shear flow and axial flow in different directions. It works in conjunction with the main stirring blades to form a multi-dimensional, three-dimensional composite flow field, which can more effectively break up clusters in the melt, disperse bubbles, and eliminate eddies, making the mixing more intense and uniform.

[0022] Optionally, the fixing block is provided with a pad, which can be engaged in the engaging groove to adjust the height of the outer cylinder.

[0023] By adopting the above technical solution, the height of the outer cylinder relative to the fixed ring can be finely adjusted by replacing the pads of different thicknesses or adjusting the snap-fit ​​position of the pads; it facilitates the connection between the adjustment hole and the jet holes of different heights, realizing jet and turbulence operation at different heights; and it allows operators to perform fixed-type fine optimization of the jet pattern based on long-term process experience.

[0024] In summary, this application includes at least one of the following beneficial technical effects: 1. The ejected molten aluminum jet can effectively impact areas outside the direct action range of the stirring blades, breaking the flow field limitations of traditional stirring and achieving active and forced homogenization throughout the entire molten pool; at the same time, the process of drawing in molten aluminum from the bottom also helps to re-roll up any potentially deposited components to participate in the circulation. 2. A real-time, adjustable two-stage flow distribution system is provided, which allows operators to flexibly adjust the jet intensity of different height areas, or even shut off the jet of a certain area, according to the specific alloy formula, melt temperature or process stage; the shielding tube is responsible for macroscopic flow field reconstruction, while the adjustable outer cylinder is responsible for microscopic flow precise control. The combination of the two realizes refined and customized management of the homogenization process. 3. The introduction of the disturbance blades increases additional shear flow and axial flow in different directions; it works in conjunction with the main stirring blades to form a multi-dimensional, three-dimensional composite flow field, which can more effectively tear apart clusters in the melt, disperse bubbles, and eliminate eddies, making the mixing more intense and uniform. Attached Figure Description

[0025] Figure 1 This is a cross-sectional view of the tank in an embodiment of this application; Figure 2 yes Figure 1 A magnified view of a portion of region A in the middle; Figure 3 This is a cross-sectional view of the stirring shaft in an embodiment of this application.

[0026] Reference numerals: 100, drive mechanism; 200, stirring shaft; 210, flow channel; 220, swirl vane; 230, jet hole; 300, stirring blade; 400, tank body; 510, shielding pipe; 511, shielding area; 512, blank area; 520, outer cylinder; 521, adjusting hole; 530, adjusting component; 531, fixing block; 532, fixing ring; 533, locking bolt; 534, snap-fit ​​groove; 535, pad; 540, disturbance blade. Detailed Implementation

[0027] The following combination Figures 1 to 3 This application will be described in further detail.

[0028] Reference Figures 1 to 3 This embodiment provides an aluminum alloy melting and casting refining homogenization device. The core of this device lies in constructing a system that combines active internal melt circulation with external adjustable flow field control to solve the problems of mixing dead zones, bottom deposition, and surface oxidation inherent in traditional stirring. The device mainly consists of a drive mechanism 100, a hollow stirring shaft 200, stirring blades 300, and a tank 400. The drive mechanism 100 drives the stirring shaft 200 and the stirring blades 300 fixed thereon to rotate, performing basic stirring. Simultaneously, the swirling blades 220 inside the stirring shaft 200 rotate with the shaft, drawing the melt upwards from the bottom and ejecting it at high speed from the jet holes 230 on the side wall, forming a strong internal circulation. The shielding pipe 510 installed on the inner wall of the tank 400 and the adjustable outer cylinder 520 sleeved outside the stirring shaft 200 work together to guide, break up, and finely control the ejected jet, thereby achieving efficient and uniform homogenization throughout the entire molten pool.

[0029] The tank 400 has a feeding port for adding materials and a discharge port for discharging materials, or the materials can be poured out by mechanical clamping.

[0030] The drive mechanism 100 is fixedly installed on the top of the tank 400. The drive mechanism 100 is a drive motor, which is located on the top wall of the tank 400. Its output shaft is connected to the upper end of the stirring shaft 200, which extends vertically into the tank 400, via a coupling, providing power to the entire stirring system. The stirring shaft 200 has a hollow structure, and the cavity formed inside it constitutes a flow channel 210 for the melt to flow. Inside the flow channel 210 of the stirring shaft 200, a swirl vane 220 is fixedly installed. The swirl vane 220 is preferably a spiral ribbon structure. When it rotates at high speed with the stirring shaft 200, it will generate an upward pumping effect on the melt in the flow channel 210, forming a low-pressure zone at the lower inlet of the flow channel 210, thereby continuously drawing in and lifting the melt from the lower part of the tank 400.

[0031] Multiple jet holes 230, connected to the internal flow channels 210, are provided on the side wall of the stirring shaft 200. These jet holes 230 are angled and not uniformly arranged, but rather non-uniformly distributed along the axial and circumferential directions of the stirring shaft 200. This arrangement allows high-speed melt jets to be ejected from different heights and directions when the stirring shaft 200 rotates, forming a three-dimensional, dynamic stirring network that effectively impacts areas difficult to reach by traditional stirring blades 300. To further enhance jet efficiency, the jet holes 230 are preferably tapered, with their diameter gradually increasing from the inside of the flow channel 210 towards the inside of the tank 400, utilizing the Venturi effect to make the jet more concentrated and achieve higher speeds.

[0032] In other embodiments, to ensure the long-term unobstructed flow of the internal circulation channel and prevent blockage caused by the cooling and solidification of molten aluminum, a high-temperature resistant non-stick coating, such as a boron nitride coating, is applied to the inner wall of the stirring shaft 200. This coating effectively reduces the adhesion of the molten metal.

[0033] In other embodiments, an annular baffle tube 510 is fixedly installed on the inner wall of the tank 400. This baffle tube 510 is located around the stirring shaft 200, and its inner diameter is larger than the outer envelope of the stirring shaft 200 and the jet orifice 230. The wall of the baffle tube 510 is not completely sealed, but rather alternately has vertically oriented baffle zones 511 and blank zones 512. The baffle zone 511 is a solid wall surface used to block and break up the molten jet impacting it; the blank zone 512 is a through hole or slot, allowing part of the jet to pass through. When the stirring shaft 200 rotates, the jet orifice 230 periodically passes through the baffle zone 511 and the blank zone 512, causing the jet to be sometimes blocked and become a fine turbulent flow, and sometimes directly ejected to impact the tank wall, thereby breaking the unidirectional vortex, inhibiting surface oxidation, and enhancing micro-mixing.

[0034] In other embodiments, to achieve precise control of the jet effect, the device further includes an annular outer cylinder 520. This outer cylinder 520 is fitted around the stirring shaft 200 via an adjusting assembly 530 and is located between the stirring shaft 200 and the aforementioned shielding tube 510. Adjusting holes 521, adapted to the shape and distribution of the jet holes 230 on the stirring shaft 200, are provided on the cylinder wall of the outer cylinder 520.

[0035] One specific embodiment of the adjusting assembly 530 includes fixing blocks 531, fixing rings 532, and locking bolts 533. Multiple fixing blocks 531 are circumferentially arranged at one end of the stirring shaft 200 near its bottom. A fixing ring 532 is rotatably fitted onto the stirring shaft 200, and the fixing ring 532 has multiple engaging grooves 534 that mate with the fixing blocks 531. The upper end of the outer cylinder 520 is detachably fixed to the stirring shaft 200 via the locking bolts 533. When it is necessary to adjust the axial position of the outer cylinder 520 to change... When adjusting the overlap between the adjustment hole 521 and the jet hole 230, the locking bolt 533 can be loosened, and the fixing ring 532 can be rotated so that its snap-fit ​​groove 534 engages with different fixing blocks 531, thereby raising or lowering the fixing ring 532 and the outer cylinder 520 to a new height position. Finally, the locking bolt 533 is tightened to fix it. In order to make more precise height adjustments, replaceable shims 535 can be set on the fixing blocks 531. By changing the thickness of the shims 535, the final installation height of the outer cylinder 520 can be slightly adjusted.

[0036] In addition, some disturbance blades 540 can be provided on the outer wall of the outer cylinder 520; these disturbance blades 540 are arranged at a certain angle with the main stirring blades 300; when the outer cylinder 520 rotates together with the stirring shaft 200, these disturbance blades 540 will generate a secondary flow field with a different direction and intensity than the flow field of the main stirring blades 300, thereby forming a more complex and three-dimensional composite flow field, further enhancing the mixing effect.

[0037] During operation, the drive mechanism 100 is activated, driving the stirring shaft 200, stirring blades 300, and internal swirl vanes 220 to rotate synchronously. The stirring blades 300 perform basic macroscopic stirring, while the swirl vanes 220 generate a strong negative pressure in the flow channel 210 inside the stirring shaft 200, drawing in the bottom melt rich in potential deposits. After pressurization, the melt is ejected at high speed from the non-uniformly distributed jet holes 230. These jets first pass through the regulating hole 521 of the outer cylinder 520 (the opening of which can be preset), and then impact the shielding pipe 510 on the tank wall. The shielding pipe 510 "crushes" and "divides" the concentrated high-energy jets, transforming them into multi-layered, multi-directional turbulence.

[0038] The entire process creates a three-dimensional circulation and mixing from bottom to top and from center to edge; it effectively eliminates composition and temperature gradients throughout the molten pool, re-rolls up and evenly disperses heavy elements deposited at the bottom, while avoiding harmful surface vortices and preventing secondary oxidation of the molten aluminum; by adjusting the height of the outer cylinder 520, the jetting pattern can be optimized for different process requirements (such as different alloys and melt volume), making the device highly efficient, adaptable, and reliable, significantly improving the quality of aluminum alloy casting products.

[0039] The above are all preferred embodiments of this application, and are not intended to limit the scope of protection of this application. Therefore, all equivalent changes made in accordance with the structure, shape and principle of this application should be covered within the scope of protection of this application.

Claims

1. An aluminum alloy melting, casting, refining, and homogenizing apparatus, comprising a drive mechanism (100), a stirring shaft (200), stirring blades (300), and a tank (400), wherein the stirring shaft (200) is driven to rotate by the drive mechanism (100) and extends into the tank (400), and the stirring blades (300) are disposed on the stirring shaft (200), characterized in that: The stirring shaft (200) has a hollow structure, forming a flow channel (210), and a swirl vane (220) is fixedly installed inside it; at least one jet hole (230) communicating with the flow channel (210) is opened on the side wall of the stirring shaft (200).

2. The aluminum alloy melting, casting, refining, and homogenizing apparatus according to claim 1, characterized in that: The inner wall of the tank (400) is fixedly provided with an annular shielding tube (510). Vertical shielding areas (511) and blank areas (512) are alternately arranged on the tube wall of the shielding tube (510). The shielding tube (510) is located outside the stirring shaft (200). The shielding area (511) and the blank area (512) intersect through part of the jet hole (230).

3. The aluminum alloy melting, casting, refining, and homogenizing apparatus according to claim 2, characterized in that: The jet holes (230) are non-uniformly distributed along the axial and circumferential directions on the sidewall of the stirring shaft (200).

4. The aluminum alloy melting, casting, refining, and homogenizing apparatus according to claim 2, characterized in that: The inner wall of the stirring shaft (200) is covered with a high-temperature resistant non-stick coating.

5. The aluminum alloy melting, casting, refining, and homogenizing apparatus according to claim 1, characterized in that: The jet orifice (230) is a conical orifice, and its diameter gradually increases from the inside of the flow channel (210) into the inside of the tank (400).

6. The aluminum alloy melting, casting, refining, and homogenizing apparatus according to claim 4, characterized in that: It also includes an annular outer cylinder (520), which is sleeved outside the stirring shaft (200) by an adjustment component (530) and located between the stirring shaft (200) and the shielding tube (510); the outer cylinder (520) has an adjustment hole (521) that matches the jet hole (230) on its wall; by driving the outer cylinder (520) to move or rotate relative to the stirring shaft (200) through the adjustment component (530), the overlap between the adjustment hole (521) and the jet hole (230) can be changed, thereby adjusting the size and position of the jet opening.

7. The aluminum alloy melting, casting, refining, and homogenizing apparatus according to claim 6, characterized in that: The adjusting assembly (530) includes a fixing block (531), a fixing ring (532), and a locking bolt (533). The fixing block (531) is located at one end of the stirring shaft (200) near the bottom of the tank (400), and multiple fixing blocks are arranged along the circumference of the stirring shaft (200). The fixing ring (532) is rotatably mounted on the stirring shaft (200), and a snap-fit ​​groove (534) is provided on the fixing ring (532). The snap-fit ​​groove (534) snaps into the fixing block (531). The locking bolt (533) is located on the outer cylinder (520) and is threadedly connected to the stirring shaft (200).

8. The aluminum alloy melting, casting, refining, and homogenizing apparatus according to claim 6, characterized in that: The outer cylinder (520) is provided with a disturbance blade (540), and the disturbance blade (540) is set at an angle to the stirring blade (300).

9. The aluminum alloy melting, casting, refining, and homogenizing apparatus according to claim 7, characterized in that: A pad (535) is provided on the fixing block (531), and the pad (535) can be snapped into the snap-fit ​​groove (534) for adjusting the height of the outer cylinder (520).

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