Flux Injector Assembly for Molten Aluminum Refining
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Solution Overview
Problem
Existing methods for refining molten aluminum alloys face challenges in effectively removing impurities like hydrogen gas, particulates, and alkali metals without using chlorine gas, which poses environmental concerns and handling burdens.
Innovation Solution
A flux injector assembly with an elongated dispensing rod and baffle plate configuration that injects flux and inert gas into molten aluminum, utilizing a dispensing rim with notches to reduce turbulence and enhance mixing, allowing for efficient impurity removal without relying on chlorine.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If chlorine gas or chlorine salts are used as flux to remove impurities from molten aluminum, then impurity removal effectiveness is improved, but environmental damage and handling burden increase
Solution Approach 1:
The patent introduces an intermediary substance (alternative flux composition without chlorine) that mediates the impurity removal process. The flux assembly delivers this chlorine-free flux into the molten aluminum, enabling effective impurity removal while eliminating the harmful environmental and handling issues associated with chlorine gas and salts.
Solution Approach 2:
The patent changes the chemical composition parameters of the flux material by formulating alternatives to traditional chlorine-based fluxes. This parameter change maintains the flux's ability to react with and remove impurities while eliminating the harmful chlorine content, thus resolving the contradiction between effectiveness and environmental harm.
2Reliability
If flux is injected into molten aluminum to remove impurities, then refinement effectiveness is improved, but turbulence and mixing complexity increase
Solution Approach 1:
The dispensing rod is segmented with multiple notches along its length, creating multiple injection points rather than a single injection zone. This segmentation distributes the flux injection across several locations, reducing localized turbulence and mixing complexity while maintaining overall refinement effectiveness.
Solution Approach 2:
The notches are strategically positioned at specific locations along the dispensing rod to optimize local flux injection characteristics. Each notch creates a controlled injection pattern tailored to the local flow conditions, reducing excessive turbulence in certain areas while ensuring adequate mixing and impurity removal effectiveness.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration improves the distribution and removal of impurities within the molten aluminum, reducing environmental impact by minimizing chlorine usage while maintaining effective refinement of molten aluminum alloys.
Implementation Method 1
a flux and/or inert gas to travel through the hollow body and be injected into the molten material through the dispensing rim
Implementation Method 2
the rate of flow of molten material is increased as it passes the dispensing rim of the elongated dispensing rod to inject and mix the flux within the molten material
Implementation Method 3
The baffle plate having a bottom edge is configured to be positioned within the molten material in the associated trough to allow the molten material to flow under the bottom edge of the baffle plate
Implementation Method 4
the rate of flow of molten material is increased as it passes the dispensing rim of the elongated dispensing rod
Implementation Method 5
Chlorine gas and chlorine salts are known to be effective in converting the alkali metals to salts which coalesce and rise to the surface of the molten material
Implementation Method 6
converting the alkali metals to salts which coalesce and rise to the surface of the molten material
Implementation Method 7
hydrogen gas diffuses into the inert gas bubbles and is removed as the particulate coalesces around the gas bubbles and rises to the top of the molten aluminum alloy
Data Source
Figure 1
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AI summary
Disclosed is a flux injector assembly and method for refining a molten material, wherein at least a portion of the material is aluminum, as it flows through a trough. A dispensing rod having a hollow body and a dispensing rim is configured to allow a flux and/or inert gas to travel through the hollow body and be injected into the molten material through the dispensing rim as the molten material flows through the trough. A baffle plate is configured to be positioned within the molten material in the associated trough to allow the molten material to flow passed the baffle plate. The elongated dispensing rod is positioned at a downstream location relative to the baffle plate. The rate of flow of molten material is increased as it passes the dispensing rim of the elongated dispensing rod to inject and mix the flux within the molten aluminum alloy.