US20080164000A1 - Casting Method and Casting Installation for Aluminium or Aluminium Alloys - Google Patents

Casting Method and Casting Installation for Aluminium or Aluminium Alloys Download PDF

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Publication number
US20080164000A1
US20080164000A1 US11/629,712 US62971205A US2008164000A1 US 20080164000 A1 US20080164000 A1 US 20080164000A1 US 62971205 A US62971205 A US 62971205A US 2008164000 A1 US2008164000 A1 US 2008164000A1
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United States
Prior art keywords
ladles
casting
station
aluminium
molten aluminium
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US11/629,712
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English (en)
Inventor
Dirk Kotze
Dawid Dewet-Smith
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Stopinc AG
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Stopinc AG
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Filing date
Publication date
Application filed by Stopinc AG filed Critical Stopinc AG
Publication of US20080164000A1 publication Critical patent/US20080164000A1/en
Abandoned legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D47/00—Casting plants

Definitions

  • the invention concerns a casting method for aluminium and/or aluminium alloys in accordance with the generic term of claim 1 and also a casting machine for implementation of the method.
  • Casting methods and casting machines for aluminium and/or aluminium alloys are known in the art, in which solid or liquid aluminium is melted in a smelting furnace and then retained in a refining furnace, from which the molten aluminium flows via a long channel to a casting station and is thereby exposed to different treatments.
  • alloy additions are added to the molten aluminium flowing down the channel and an inert purging gas (argon) is injected, before the melt, via a filter, reaches the casting station, in which it is cast into semi-finished products (cf. FIG. 1 in which an ordinary casting machine for aluminium is shown diagrammatically). Only limited homogenisation of the molten aluminium is possible.
  • the treatment times are tied to the casting process and thus predetermined and limited in terms of time.
  • the individual treatment stations have to be co-ordinated with each other perfectly. If one of the stages of this in-line machine does not function, then the entire casting machine has to be shut down.
  • the long channel through which the molten aluminium flows means a loss of temperature so that the material has to be overheated in the refining furnace so that a sufficient temperature can be reached on arrival at the casting station.
  • Extensive casting times mean that the smelting and refining furnace has to be available for the entire casting time, before the next batch of melt is used.
  • the energy consumption of the furnaces is correspondingly high. Normally, reverbatory furnaces with hydrocarbon fuel are used, giving rise to the disadvantage of a rapid absorption of hydrogen from the burner flame. Furthermore, greenhouse gases and other pollutants which load the atmosphere are also created.
  • the long, open channel through which the molten aluminium runs also means that the metal absorbs hydrogen from the atmosphere and causes the formation of dross.
  • the present invention is based on the problem of proposing a more economical and more flexible casting method for aluminium and/or aluminium alloys and also of creating a casting machine to implement the method, enabling an optimal period for the treatment and casting of the molten aluminium and thereby achieving an improved quality of the semi-finished products to be produced.
  • This problem is solved according to the invention by a casting method with the characteristics of claim 1 and by a casting machine with the characteristics of claim 13 .
  • this phase of the method is decoupled in terms of time from the actual casting process.
  • the individual treatments are no longer fixed and temporally restricted, but can if necessary be adapted until the desired quality of the molten aluminium to be cast is achieved in the relevant ladle.
  • the method according to the invention is considerably more efficient than the in-line method since there is no longer any need for large refining furnaces. If used at all, the furnaces are used for smelting and heating, but not for keeping warm over longer periods. These can be in the form of energy-efficient and ecologically advantageous induction furnaces.
  • FIG. 1 diagram of an embodiment of a state of the art casting machine for aluminium
  • FIG. 2 diagram of an embodiment of an aluminium casting machine according to the invention.
  • FIG. 1 shows a state of the art casting machine 1 for aluminium and/or aluminium alloys.
  • Liquid or solid aluminium is introduced as basic material in a first stage or station 2 , which comprises a smelting furnace 3 and a refining furnace 4 attached thereto.
  • the aluminium can be supplied from a potroom by means of a transfer ladle 5 or as a scrap batch.
  • the furnaces 3 , 4 are usually large reverbatory furnaces using hydrocarbon fuel.
  • the melt produced in the smelting furnace 3 is heated in the refining furnace 4 to the necessary temperature and partly homogenised by agitation.
  • the molten aluminium Once the molten aluminium has reached the necessary temperature, it is guided out of the refining furnace 4 via a long channel 6 to a casting station 7 , whereby it flows through various treatment stations 11 , 12 , which together with a filter 13 connected upstream of the casting station 7 form a second stage 10 of the casting machine 1 .
  • various treatment stations 11 , 12 which together with a filter 13 connected upstream of the casting station 7 form a second stage 10 of the casting machine 1 .
  • various alloy additions are added to the molten aluminium. Gas purification occurs in the treatment station 12 .
  • the casting station 7 in which the molten aluminium is cast into semi-finished products, can be operated continuously or semi-continuously in a way known in the art and therefore not described in more detail.
  • the treatment periods in the second stage 10 are tied to the casting process to be carried out in the casting station 7 and thus predetermined and restricted.
  • the individual treatment stations 11 , 12 must be perfectly synchronised with each other in their function. If one of the stages of this in-line machine does not function, then the entire casting machine 1 has to be shut down.
  • the long channel through which the molten aluminium flows means a loss of temperature so that the material has to be overheated (e.g. to 730° C.) in the refining furnace 4 so that a sufficient temperature (e.g. 700° C.) can be reached on arrival at the casting station 7 .
  • Extensive casting times mean that the smelting and refining furnace 4 has to be available for the entire casting time, before the next batch of melt is used.
  • the energy consumption of the furnaces 3 , 4 is correspondingly high.
  • FIG. 2 shows a diagram of a casting machine 1 according to the invention for aluminium and/or aluminium alloys.
  • the first stage of the casting method according to the invention occurs in a filling station 21 , in which hot molten aluminium is poured into a number of ladles 25 .
  • the ladles can for example have a capacity of 15 t. Either liquid, hot (temperature approx.
  • aluminium from a potroom can be poured directly into the ladles 25 using transfer ladles or at least one, preferably several, furnaces 22 , 23 , 24 are assigned to the filling station 21 and are responsible for delivering the molten aluminium, whereby in addition to liquid aluminium, scrap aluminium or ingots provided for recasting can serve as basic material.
  • the molten aluminium can for example be poured into one of the ladles 25 at half-hourly intervals.
  • molten aluminium of varying quality can be poured from the individual furnaces into the ladles 25 , whereby the filling of the ladles 25 with molten aluminium, possibly also with mixed material from various furnaces 22 , 23 , 24 , can be computer-controlled.
  • electrical induction furnaces can be used as furnaces 22 , 23 , 24 , which are considerably more efficient in energy terms than reverbatory furnaces.
  • These can for example be induction furnaces with a capacity of 20 t, from each of which 15 t of molten aluminium can be poured into one of the ladles 25 and the remaining 5 t can serve when smelting a further charge.
  • the casting machine 1 has a purification and preparation station 30 , from which purified and pre-heated ladles 25 a are transported to the filling station 21 for filling (ladles 25 on a transport section are generally designated in FIG. 2 by the letter T).
  • a purification and preparation station 30 from which purified and pre-heated ladles 25 a are transported to the filling station 21 for filling (ladles 25 on a transport section are generally designated in FIG. 2 by the letter T).
  • the molten aluminium poured from the furnaces 22 , 23 , 24 operated at a temperature of approx. 800° C. can remain for longer in the ladles 25 until it falls to the typical casting temperature of 700° C., as would be the case without pre-heating.
  • the dross is skimmed off the surface of the melting bath (dedrossing) by tilting the ladle.
  • the ladles 25 filled in the filling station 21 are transported to a treatment station 32 , in which the second stage of the casting process occurs.
  • Firstly alloy additions are added to the molten aluminium (cf. the ladles referred to as 25 b in FIG. 2 ).
  • the molten aluminium is homogenised and purified (cf. ladles 25 c ).
  • the ladles are placed beneath a rotary impeller immersible in the respective ladles 25 c to inject inert gas, e.g.
  • argon or nitrogen whereby combined hydrogen removal, homogenisation and/or thermal regulation of the molten aluminium can occur.
  • the injection of argon eliminates the absorption of hydrogen from the humidity present in the atmosphere and the formation of dross is reduced.
  • small amounts of chlorine can be added into the purge gas.
  • the ladles 25 can be kept in storage stations provided for this purpose (in FIG. 2 such storage stations are generally designated by the letter S), until a casting station 33 or 34 is available.
  • the casting machine 20 preferably has several such casting stations (two shown in FIG. 2 ), to which the ladles 25 can be transported from the treatment or storage station, and in which the molten aluminium is cast into semi-finished products.
  • the temperature of the molten aluminium is maintained advantageously by covering the ladles 25 with a cover.
  • the temperature in the ladles 25 can be reduced by the injection of argon through a porous plug in the base of the ladle or maintained or increased by means of a small burner built into the ladle cover.
  • the emptying of the ladles 25 d at the respective casting station 33 , 34 occurs through the base of the ladle by means of controllable opening of a sliding closure, whereby the outflowing molten aluminium is guided into a collector spout, preferably encased by an inert gas.
  • a collector spout preferably encased by an inert gas.
  • argon can be blown in through the porous plug in the ladle base, agitating and purifying the melt.
  • the casting stations 33 , 34 are each equipped with a filter system in a way known in the art and are operated continuously or semi-continuously.
  • the ladles 25 d After emptying the ladles 25 d , these are transported to the aforementioned cleaning and preparation station 30 where they are cleaned (cf. ladle 25 e ) and prepared for re-use, in particular pre-heated (cf. ladle 25 a ).
  • the emptied ladles can also be stored until further use in the storage stations S provided for this purpose.
  • the casting machine according to the invention is equipped with a control system to control the charges to be poured out of the individual furnaces 22 , 23 , 24 into the individual ladles 25 , the alloy additions, heating, cooling, gas supply and treatment times, so that the molten aluminium reaches the casting stations 33 , 34 in the desired quality, at the desired temperature and fully homogenised.
  • this process phase is decoupled in terms of time from the actual casting process.
  • the individual treatments are no longer predetermined and limited in terms of time, but can be adjusted as required, until the desired quality of the molten aluminium to be cast is achieved in the respective ladle. If, for example, a lower hydrogen content is required, the gas purification period can be extended. This option did not exist in the traditional in-line process according to FIG. 1 .
  • the production output of the casting machine depends on the actual casting process, solely at the casting stations, which can be continued until the supply of the treated molten aluminium to the casting stations is interrupted as required.
  • the method according to the invention is considerably more efficient than the in-line process, since there is no longer any need for large refining furnaces. If used at all, the furnaces are used for smelting and heating, but not for keeping the melt warm over longer periods. These can be in the form of energy-efficient and ecologically advantageous induction furnaces. By pre-heating the ladles, the smelting temperature achievable in the furnaces can be lower.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Manufacture And Refinement Of Metals (AREA)
  • Casting Support Devices, Ladles, And Melt Control Thereby (AREA)
  • Continuous Casting (AREA)
  • Vertical, Hearth, Or Arc Furnaces (AREA)
  • Mold Materials And Core Materials (AREA)
  • Prevention Of Electric Corrosion (AREA)
US11/629,712 2004-06-16 2005-06-16 Casting Method and Casting Installation for Aluminium or Aluminium Alloys Abandoned US20080164000A1 (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
EP04405366.8 2004-06-16
EP04405366A EP1607156B1 (de) 2004-06-16 2004-06-16 Giessverfahren und Giessanlage für Aluminium bzw. Aluminiumlegierungen
PCT/EP2005/006486 WO2005123304A2 (de) 2004-06-16 2005-06-16 Giessverfahren und giessanlage für aluminium bzw. aluminiumlegierungen

Publications (1)

Publication Number Publication Date
US20080164000A1 true US20080164000A1 (en) 2008-07-10

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US11/629,712 Abandoned US20080164000A1 (en) 2004-06-16 2005-06-16 Casting Method and Casting Installation for Aluminium or Aluminium Alloys

Country Status (12)

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US (1) US20080164000A1 (de)
EP (1) EP1607156B1 (de)
JP (1) JP2008502483A (de)
CN (1) CN1976773A (de)
AT (1) ATE421398T1 (de)
AU (1) AU2005254220A1 (de)
CA (1) CA2570361A1 (de)
DE (1) DE502004008913D1 (de)
MX (1) MXPA06014600A (de)
RU (1) RU2007101384A (de)
WO (1) WO2005123304A2 (de)
ZA (1) ZA200609947B (de)

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN104259396A (zh) * 2014-07-10 2015-01-07 陕西国德电气制造有限公司 枕梁制备方法
CN115213393A (zh) * 2022-07-09 2022-10-21 江苏政田新材料有限公司 一种锚链轮铸造用钢水过滤装置

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CA2684354A1 (en) * 2007-04-16 2008-10-23 Stopinc Aktiengesellschaft Casting method and casting system for aluminium or aluminium alloys
CN102151816B (zh) * 2011-03-10 2013-04-24 山东滨州渤海活塞股份有限公司 铝活塞自动铸造机

Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4959101A (en) * 1987-06-29 1990-09-25 Aga Ab Process for degassing aluminum melts with sulfur hexafluoride
US5272720A (en) * 1990-01-31 1993-12-21 Inductotherm Corp. Induction heating apparatus and method

Family Cites Families (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB8428251D0 (en) * 1984-11-08 1984-12-19 Alcan Int Ltd Treating aluminium
DE3736117A1 (de) 1987-10-26 1989-05-03 Krupp Gmbh Anlage zur herstellung von stahl, insbesondere ministahlwerksanlage
JPH09182958A (ja) * 1995-12-28 1997-07-15 Kusano Sangyo Kk 溶湯取鍋の自動搬送装置
JP3680252B2 (ja) * 1999-06-29 2005-08-10 Ｊｆｅスチール株式会社 蓄熱式バーナの使用方法
JP3621405B2 (ja) * 2000-12-27 2005-02-16 株式会社豊栄商会 容器
JP3323489B1 (ja) * 2000-12-27 2002-09-09 株式会社豊栄商会 溶融金属供給用容器
JP2002205162A (ja) * 2001-01-05 2002-07-23 Hoei Shokai:Kk 金属供給システム

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4959101A (en) * 1987-06-29 1990-09-25 Aga Ab Process for degassing aluminum melts with sulfur hexafluoride
US4959101B1 (de) * 1987-06-29 1992-02-25 Aga Ab
US5272720A (en) * 1990-01-31 1993-12-21 Inductotherm Corp. Induction heating apparatus and method

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN104259396A (zh) * 2014-07-10 2015-01-07 陕西国德电气制造有限公司 枕梁制备方法
CN115213393A (zh) * 2022-07-09 2022-10-21 江苏政田新材料有限公司 一种锚链轮铸造用钢水过滤装置

Also Published As

Publication number Publication date
EP1607156B1 (de) 2009-01-21
JP2008502483A (ja) 2008-01-31
WO2005123304A3 (de) 2006-08-10
RU2007101384A (ru) 2008-07-27
ATE421398T1 (de) 2009-02-15
WO2005123304A2 (de) 2005-12-29
CN1976773A (zh) 2007-06-06
CA2570361A1 (en) 2005-12-29
EP1607156A1 (de) 2005-12-21
AU2005254220A1 (en) 2005-12-29
ZA200609947B (en) 2008-11-26
MXPA06014600A (es) 2007-05-16
DE502004008913D1 (de) 2009-03-12

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