Segmented Aluminum Launder for Thermal Shock Resistance
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Solution Overview
Problem
Traditional aluminum-based launder systems suffer from internal stress, cracking, contamination, and inefficiencies in high-temperature alloy smelting due to their integrally-formed and single-structured design, which limits their thermal shock properties and requires frequent replacement, leading to increased costs and reduced productivity.
Innovation Solution
An aluminum-based ultra-thin launder with a segmented structure and layered composition, featuring a refractory, transition, reinforcement, and protective layers, connected via splicing or snapping mechanisms, reduces internal stress and allows for targeted component replacement, enhancing thermal shock resistance and ease of use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional one-step molding process is used to manufacture launder, then manufacturing process is simple, but the launder exhibits large internal stress, clamping gap, unstable structure, and poor thermal shock property
Solution Approach 1:
The launder body is divided into multiple layers (refractory layer, transition layer, reinforcement layer, protective layer) formed through sequential coating processes. This segmentation allows each layer to be optimized independently for its specific function while reducing internal stress through controlled layer-by-layer construction, thereby improving structural stability without requiring complex one-step molding
2Strength
If traditional integrally-formed launder structure is used, then structural integrity is maintained, but the launder is bulky, cannot be disassembled, and difficult to repair
Solution Approach 1:
The launder is designed with a segmented structure where the lining layers can be separated from the outer shell through detachable connection mechanisms. This allows the functional layers to be removed and replaced independently without damaging the overall structure, enabling easy repair and maintenance while maintaining structural integrity during operation
3Reliability
If traditional thick-walled launder is used to reduce internal stress, then structural stability improves, but material consumption increases and cleaning time extends
Solution Approach 1:
The launder employs composite material construction with four distinct layers: refractory layer for heat resistance, transition layer for stress distribution, reinforcement layer for structural strength, and protective layer for surface durability. This composite structure achieves the required structural stability with optimized thickness distribution, reducing overall material consumption compared to traditional uniform thick-walled design
4Ease of manufacture
If traditional single-structured launder is used, then manufacturing is straightforward, but thermal shock property is poor and service life is short
Solution Approach 1:
The launder body is disposed with four functional layers obtained by sequential coating: refractory layer, transition layer, reinforcement layer, and protective layer. This multi-layer segmentation allows each layer to be optimized for specific thermal and mechanical properties, significantly improving thermal shock resistance and service life while maintaining manufacturing feasibility through standardized coating processes
Data Source
AI summary
The present invention relates to the field of alloy-smelting facilities, and provides an aluminum-based ultra-thin launder. The launder has a body with a wall thickness of 12 mm to 25 mm. The body has a segmented structure, including a part of alloy in, a first launder, a second launder and a part of alloy out that are connected in sequence. The body of the launder provided in the present invention is lighter and thinner. The cost of production and use is reduced due to the significantly-decreased wall thickness and weight. The connection mode for components of the body is changed, which is beneficial to the replacement, and fundamentally lowers the risk of a repair material contaminating melted alloy.