CN112410590A - Aluminum bar manufacturing process - Google Patents
Aluminum bar manufacturing process Download PDFInfo
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- CN112410590A CN112410590A CN201910781192.7A CN201910781192A CN112410590A CN 112410590 A CN112410590 A CN 112410590A CN 201910781192 A CN201910781192 A CN 201910781192A CN 112410590 A CN112410590 A CN 112410590A
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C1/00—Making non-ferrous alloys
- C22C1/02—Making non-ferrous alloys by melting
- C22C1/026—Alloys based on aluminium
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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
- B22D1/00—Treatment of fused masses in the ladle or the supply runners before casting
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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
- B22D27/00—Treating the metal in the mould while it is molten or ductile ; Pressure or vacuum casting
- B22D27/04—Influencing the temperature of the metal, e.g. by heating or cooling the mould
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C1/00—Making non-ferrous alloys
- C22C1/06—Making non-ferrous alloys with the use of special agents for refining or deoxidising
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Abstract
The invention relates to the technical field of aluminum material smelting, and discloses an aluminum bar manufacturing process, which comprises the following steps: s1, preparing for smelting; s2, primary smelting; s3, refining; s4, degassing and filtering; s5, sampling and analyzing; s6, standing and forming; s7, grain refinement; s8, vertical shaft casting; s9, sawing; s10, detecting, packaging and frying ash. The scheme melts the waste aluminum, the aluminum ingot and the magnesium ingot together so as to achieve the aim of recycling the waste aluminum and control the proportion of the waste aluminum, so as to avoid the production difficulty caused by excessive waste aluminum; and the design of the ash frying step further recycles the waste aluminum in the waste slag generated in the smelting process, thereby improving the recycling rate of the waste aluminum.
Description
Technical Field
The invention relates to the technical field of aluminum material smelting, in particular to an aluminum bar manufacturing process.
Background
Aluminum is a silvery-white light metal, and is often formed into rods, sheets, foils, powders, ribbons, and wires. Aluminum has special chemical and physical properties, is light in weight and firm in texture, and has good ductility, electrical conductivity, thermal conductivity, heat resistance and nuclear radiation resistance, and aluminum alloy are one of the most economical and applicable materials with wide application at present and are important basic raw materials for national economic development.
The aluminum bar is one of aluminum products, is a kind of intermediate product with a very large usage amount in aluminum alloy, and is usually cylindrical. The aluminum bars can be generally divided into 8 major categories according to different metal elements, including 1000 series aluminum bars, 2000 series aluminum bars, 3000 series aluminum bars, 4000 series aluminum bars, 5000 series aluminum bars, 6000 series aluminum bars, 7000 series aluminum bars and 8000 series aluminum bars, and are mainly used as blanks of extrusion products such as building profiles, irrigation pipes, automobile accessories, barriers and the like or blanks of forging products such as airplane skin, fuselage frames, propellers and the like.
Generally, the preparation of aluminum bar mainly includes the technological processes of melting, batching, degassing, deslagging, refining, casting, etc., and the main processes are as follows:
preparing materials: according to the specific alloy grades to be produced, the addition amounts of various alloy components are calculated, and various raw materials are reasonably matched.
Smelting: the prepared raw materials are added into a smelting furnace according to the process requirements for melting, and the mixed slag and gas in the melt are effectively removed by means of degassing, deslagging and refining.
Casting: and cooling and casting the smelted aluminum liquid into round casting rods with various specifications through a deep well casting system under certain casting process conditions.
However, finished aluminum ingots are used as raw materials of aluminum bars in the prior art, and a large amount of waste aluminum products exist in the market, so that if the waste aluminum can be effectively recycled, the production cost can be reduced, the excess of productivity can be relieved, and the recycling of aluminum resources is facilitated. Therefore, there is a need for an aluminum bar manufacturing process with high recycling efficiency and an effect of recycling waste aluminum.
Disclosure of Invention
Aiming at the defects in the prior art, the invention aims to provide the aluminum bar manufacturing process which has the function of recycling waste aluminum and is high in recycling rate.
The technical purpose of the invention is realized by the following technical scheme:
an aluminum bar manufacturing process comprises the following steps:
s1, smelting preparation: designing raw material proportion according to product characteristics, and directly adding aluminum ingots, magnesium ingots and waste aluminum without a coating into a heat accumulating type natural gas smelting furnace by a forklift;
s2, primary smelting: smelting: after the raw materials are added, closing a furnace door, controlling the temperature of a hearth to be 1200 +/-15 ℃, and maintaining the temperature of a furnace body to be 900 +/-15 ℃; simultaneously, carrying out electromagnetic stirring on the aluminum melt; after the materials are in a liquid state, opening a furnace door, adding magnesium ingots, alloy additives and slag-forming agents, closing the furnace door, and continuing stirring until the materials are completely melted; skimming: in the stirring process, skimming is carried out when the thickness of the floating waste residue is more than 5mm, and 40-50% of the waste residue is skimming;
s3, refining: after the aluminum liquid is completely melted, guiding the aluminum liquid in the furnace from a closed diversion trench above the smelting furnace to a heat accumulating type natural gas heat preservation furnace for refining; the temperature of the holding furnace is kept at 700-760 ℃; meanwhile, impurities and bubbles in the aluminum liquid are removed in a mode of adding a slagging agent, a refining agent and filling nitrogen, and the nitrogen supply speed is 150 and 160m during the dry distillation/h; skimming is not carried out periodically, and the skimming principle is the same as that of the skimming step in the step S2;
s4, degassing and filtering: firstly, introducing nitrogen from the bottom of the heat preservation furnace through an online processing device, stirring and smashing the nitrogen into small bubbles by a graphite rotor, gradually enlarging the small bubbles when the small bubbles rise, and converting hydrogen atoms in the aluminum liquid into hydrogen and then bringing the hydrogen atoms to the surface of the aluminum liquid for combustion; then guiding the slag-containing aluminum liquid on the surface layer from an overflow port of the holding furnace to an online treatment device, and filtering the waste slag through a filtering device of an online treatment facility.
S5, sampling analysis: sampling at the furnace door of the heat preservation furnace, detecting the components of the heat preservation furnace, and continuously adding aluminum ingots and magnesium ingots into unqualified aluminum liquid until the aluminum liquid meets the requirements;
s6, standing and forming: standing and forming the qualified filtrate in a furnace;
s7, grain refinement: conveying the aluminum liquid in the heat preservation furnace into casting equipment through a closed guide groove, and arranging a wire feeder at the front end of the guide groove to continuously feed aluminum, titanium and boron into the conveyed aluminum liquid;
s8, vertical shaft casting: guiding the refined aluminum liquid into a feed chute of the cast rod mold from the closed guide chute for online treatment, cooling, gradually turning the aluminum liquid into softened aluminum alloy, slowly extruding from the mold, and solidifying and molding;
s9, sawing: conveying the aluminum bar to an automatic bar sawing machine by using a forklift, and sawing by using a water jet cutter;
s10, detecting and packaging: sampling the sawed aluminum bar, detecting a section of the sawed sample with the thickness of 0.3-0.4cm, and returning a product which is unqualified in detection result to the smelting furnace for reuse after all the products are sawed into sections;
also comprises the ash frying step:
a. stirring and separating: guiding the waste residues generated in the steps S2 and S3 into an ash frying machine for stirring, and adding clear water during stirring; stirring for 8-10min to see the gradual blackening of the aluminum ash surface in the pan of the ash frying machine, wherein the aluminum water with high specific gravity sinks to the pan bottom and flows out along the holes of the pan bottom, and finally enters a smelting furnace for reuse; the ash with low specific gravity is suspended on the surface of the upper end of the pot to complete the separation.
By adopting the technical scheme, the waste aluminum, the aluminum ingot and the magnesium ingot are smelted together, so that the aim of recovering the waste aluminum is fulfilled, and the proportion of the waste aluminum is controlled, so that the production difficulty caused by excessive waste aluminum is avoided; and the design of the ash frying step further recycles the waste aluminum in the waste slag generated in the smelting process, thereby improving the recycling rate of the waste aluminum.
The invention is further set that in the ash frying step, when the aluminum liquid is agglomerated in the stirring process, the stirring blades are rotated in a positive and negative cross mode to break up the agglomerates.
By adopting the technical scheme, the agglomerates are broken up by positive and negative cross rotation in the stirring process, so that the aluminum liquid is fully heated, the aluminum ash and the aluminum liquid are conveniently separated, and the aluminum liquid is favorably recycled.
The invention is further configured that the ash frying step further comprises the following steps:
b. waste treatment: after the separation is finished, the waste materials in the ash frying hopper are poured into a storage tank of the ash frying machine, the waste materials are indirectly cooled by clear water, and the whole process is kept in a semi-closed state.
c. Screening: screening large-particle waste residues in a storage tank, and then sending the large-particle waste residues into a waste treatment process for further cooling, stirring and separating; and treating the residual small-particle waste residues as solid wastes.
Through adopting above-mentioned technical scheme, the aluminium ash that separates in the ash frying machine is further sieved to this most aluminium scraps with remaining in the aluminium ash are retrieved, have further improved aluminium scrap's recycle ratio.
The invention is further configured that in the step S1, the surface of the recovered aluminum scrap needs to be polished, and after polishing is completed, the scrap on the surface of the aluminum scrap is completely sucked.
By adopting the technical scheme, the surface of the aluminum scrap is polished once before the aluminum scrap is charged into the furnace, so that impurities, coatings, paint and other non-aluminum substances on the surface of the aluminum scrap are removed, the impurities are prevented from entering the smelting furnace, and the purity of the aluminum rod is ensured.
The invention is further configured that, in the step S8, talc powder for lubrication is coated in the mold during the processing.
By adopting the technical scheme, the talcum powder is coated in the cast rod die, so that the aluminum rod is extruded, the possibility of frosting the surface of the aluminum rod is reduced, and the effect of improving the surface smoothness of the aluminum rod is achieved.
The invention is further configured that in the step S9, leftover bits left after sawing are sent to the smelting furnace for reuse.
By adopting the technical scheme, the leftover materials left after sawing are sent into the smelting furnace for recycling, so that the aluminum scrap generated in the process is fully recovered, and the production cost is further reduced.
The present invention further provides that, in step S10, the detection mode is as follows: alkali washing: putting the test article into an alkaline washing tank for soaking treatment, wherein the component of the tank liquid is preferably a sodium hydroxide solution with the concentration of 14-16%, and the alkaline washing temperature is kept at room temperature for 5-10 minutes; acid washing: cleaning the test article by using nitric acid with the concentration of 18% -20%; flushing: the test product after the acid washing enters a water washing tank for washing, and the washing is carried out for three minutes while the room temperature is maintained; and fourthly, detection: and detecting the test product by adopting a visual method or an enlarged mirror within 20 times, and returning the unqualified product to the smelting furnace for reuse after the product is sawed into sections.
By adopting the technical scheme, the surface of the test article is brightened by the alkali washing process, and the surface of the test article can be thoroughly stripped of hanging ash and residual alkali liquor after acid neutralization, so that a bright basic metal surface is exposed, the influence of the residue on the surface of the test article on a detection result is eliminated, the manual detection is facilitated, and the accuracy of manual detection is improved.
The present invention further provides that, in the step S10, another preferred detection method is as follows: alkali washing: putting the test article into an alkaline washing tank for soaking treatment, wherein the component of the tank liquid is preferably a sodium hydroxide solution with the concentration of 14-16%, and the alkaline washing temperature is kept at room temperature for 5-10 minutes; acid washing: cleaning the test article by using nitric acid with the concentration of 18% -20%, and removing hanging ash and residual alkali liquor; flushing: the test product after the acid washing enters a water washing tank for washing, and the washing is carried out for three minutes while the room temperature is maintained; and fourthly, detection: detecting the test product by adopting a visual method or an enlarged mirror within 20 times, feeding the qualified product into the next detection procedure, and returning the unqualified product to the smelting furnace for reuse after the unqualified product is sawed into sections; mixed pickling: adding nitric acid, hydrofluoric acid and hydrochloric acid into a pickling tank by using a metering pump for preparation, wherein the preparation ratio is hydrofluoric acid: hydrochloric acid: nitric acid = 1: 5: 15, controlling the temperature in the mixed pickling process to be room temperature for 5-10 minutes.
By adopting the technical scheme, on the basis of visual detection, the mixed acid is used for removing an oxide layer generated on the surface of the test article in the detection process and eliminating part of metal on the surface of the test article, so that an operator can observe crystal grains of the test article and judge whether the test article is qualified.
The invention is further configured that in the step S1, the surface of the recycled waste aluminum is polished before charging, chips on the surface of the waste aluminum are sucked and collected after polishing is completed, and the waste acid generated in the step S10 is reused in the collected chips to recycle aluminum in the chips in a solution form.
Through adopting above-mentioned technical scheme, the waste acid that produces in with the testing process mixes with the piece that the aluminium scrap of polishing was collected, utilizes the waste acid to dissolve the remaining aluminium in the piece to this waste that reduces aluminium, and the harm that the direct discharge of waste acid brought has been avoided to the reutilization waste acid.
In conclusion, the beneficial technical effects of the invention are as follows:
1. the invention melts the waste aluminum, aluminum ingot and magnesium ingot together, so as to achieve the purpose of recovering the waste aluminum, and controls the proportion of the waste aluminum, so as to avoid the production difficulty caused by excessive waste aluminum; the design of the ash frying step further recycles the waste aluminum in the waste slag generated in the smelting, thereby improving the recycling rate of the waste aluminum;
2. the aluminum ash separated from the ash frying machine is further screened, so that most of residual aluminum scrap in the aluminum ash is recovered, and the recovery utilization rate of the aluminum scrap is further improved;
3. the surface of the aluminum scrap is polished once before charging, so that impurities, coatings, paints and other non-aluminum substances on the surface of the aluminum scrap are removed, the impurities are prevented from entering a smelting furnace, and the purity of an aluminum rod is ensured.
Drawings
FIG. 1 is a schematic overall flow diagram of the present invention;
FIG. 2 is a schematic view of the flow of test packages in example 2 of the present invention;
FIG. 3 is a schematic view of the flow of test packages in example 3 of the present invention.
Detailed Description
The present invention will be described in further detail with reference to the accompanying drawings.
Example 1: an aluminum bar manufacturing process, as shown in fig. 1, includes the following steps:
s1, smelting preparation:
proportioning: the raw material proportion is designed according to the product characteristics.
Processing raw materials: and polishing the surface of the recovered aluminum scrap, and completely sucking and collecting the scraps on the surface of the aluminum scrap after polishing.
And thirdly, directly adding the aluminum ingot, the magnesium ingot and the waste aluminum without the coating into the heat accumulating type natural gas smelting furnace by a forklift.
S2, primary smelting:
smelting: closing a furnace door of the smelting furnace after adding the raw materials, and keeping the smelting process in a closed state; the smelting furnace adopts natural gas for combustion heat supply, the temperature of a hearth is controlled to be 1200 +/-15 ℃, and the temperature of a furnace body is maintained to be 900 +/-15 ℃; in order to improve the uniformity of the alloy components of the aluminum melt and the uniformity of the temperature, the aluminum melt is stirred in an electromagnetic stirring mode; after the materials become liquid, opening the furnace door, adding magnesium ingots, alloy additives and slag-forming agents, closing the furnace door, and continuing stirring until the materials are completely melted; the alloy additives comprise silicon ingots, titanium agents, copper ingots and zinc ingots, and the additives are added in different types and proportions according to different grades of aluminum bars.
Skimming: in the stirring process, impurities in the aluminum liquid react with the slag removing agent to generate metal oxides (waste residues), the waste residues are easy to float on the aluminum liquid, the floating waste residues can prevent the aluminum liquid from directly contacting with the atmosphere, and skimming is carried out when the thickness of the floating waste residues is more than 5mm, so that 40-50% of the waste residues are skimming.
S3, refining: the pinhole defect of the aluminum alloy casting is the most prominent reason for casting scrap, and the generation of the pinhole mainly comes from the slag inclusion content and the hydrogen content in the melt. After the aluminum liquid is completely melted and no smoke is generated, guiding the aluminum liquid in the smelting furnace from a closed diversion trench above the smelting furnace to a heat accumulating type natural gas heat preservation furnace for refining; the heat preservation furnace adopts natural gas combustion for heat supply, and the temperature of the furnace body is kept at 700-760 ℃; at the moment, in order to improve the purity of the finished aluminum alloy product, impurities and bubbles in the aluminum liquid need to be removed, a mode of adding a slag former and a refining agent and filling nitrogen is adopted, and the nitrogen gas supply speed is 150 and 160m for cultivation/h; skimming is performed irregularly, and the skimming principle is the same as that of the skimming step in the step S2.
S4, degassing and filtering: the degassing mode is that nitrogen is introduced from the bottom of the heat preservation furnace through the online processing device and is stirred and smashed into small bubbles by the graphite rotor, when the small bubbles of the nitrogen move to the liquid level at the bottom of the aluminum liquid, hydrogen dissolved in the aluminum liquid is changed into an adsorption state from a dissolution state when encountering a nitrogen-aluminum liquid phase interface, gas atoms in the adsorption layer react to generate hydrogen molecules, and the hydrogen rises to the surface of the aluminum liquid to be burnt along with the growth of the bubbles. When small bubbles of nitrogen gas move from the bottom of the aluminum liquid to the liquid level, the suspended impurity particles in the aluminum liquid are pulled, and the impurity particles collide with each other, are gathered and grow up; when the impurities collide with the floating bubbles, the impurities are captured by the bubbles and are brought to the liquid level, so that the slag removing effect is achieved; then discharging the slag-containing aluminum liquid on the surface layer from an overflow port of the holding furnace, guiding the slag-containing aluminum liquid to an online treatment device through a diversion trench, and filtering the slag through a filtering device of an online treatment facility.
S5, sampling analysis: sampling at the furnace door of the heat preservation furnace, detecting the components of the heat preservation furnace by using a direct-reading spectrometer, and continuously adding aluminum ingots and magnesium ingots into unqualified aluminum liquid until the aluminum liquid meets the requirements;
s6, standing and forming: and standing and forming the qualified filtrate in a furnace.
S7, grain refinement: in order to have excellent refining effect on the product, improve the surface quality of the casting and obtain fine isometric crystals on the casting, particularly reduce rough products and columnar products which are eliminated by the cold shut of the casting, effectively overcome casting cracks and improve the appearance of the casting. In the step, aluminum liquid in the heat preservation furnace is conveyed into casting equipment through a closed guide groove, a wire feeder is arranged at the front end of the guide groove, and aluminum, titanium and boron are continuously added into the conveyed aluminum liquid through the wire feeder.
S8, vertical shaft casting: guiding the refined aluminum liquid into a trough of a casting rod mold from a closed diversion trench with online processing capacity, gradually cooling the aluminum liquid in the trough, gradually changing the fluidity into softened aluminum alloy, and slowly extruding the softened aluminum alloy from the mold (round ingot crystallizer) and solidifying and molding; the talcum powder is smeared in the die in the processing process to play a role in lubrication.
S9, sawing: because the surface of the cast rod can form cold shut and burrs with certain thickness in the casting process of the aluminum alloy cast rod, the cast rod is required to remove surface defects in order to avoid the influence of the cold shut and the burrs on the surface quality of the hot-rolled aluminum alloy plate. This step transports the aluminium bar to automatic rod sawing machine with fork truck and saw cuts, saw cuts the in-process and uses the water sword cutting mode. Meanwhile, the leftover materials left after sawing are sent into a smelting furnace for recycling.
S10, detecting and packaging: sampling the sawed aluminum bar, extracting one sample from each batch of products, enabling a section of the sawed sample with the thickness of 0.3-0.4cm to enter a laboratory for detection, and returning all the unqualified products to the smelting furnace for reuse after being sawed into sections.
Because the residual rate of the alloy aluminum in the waste residues generated in the smelting and refining processes is still high (accounting for 40% -60%), the invention sends the waste residues generated in the smelting and refining processes into an ash frying machine for ash frying, and returns the separated alloy aluminum to the smelting furnace for reuse, thereby improving the utilization rate of the waste aluminum and reducing the production cost; the ash frying method comprises the following specific steps:
a. stirring and separating: introducing the waste residue into an ash frying machine, stirring in the ash frying machine, and adding clear water during stirring to accelerate separation; stirring for 8-10min to make the surface of aluminum ash in the pan gradually blacken, and the aluminum water with high specific gravity sinks to the bottom of the pan and flows out along the bottom hole of the pan, and finally enters a smelting furnace for reuse; the ash with low specific gravity is suspended on the surface of the upper end of the pot to complete the separation.
In the stirring process, when the caking phenomenon is generated, the stirring blades are rotated in a positive and negative cross way to break up the caking.
b. Waste treatment: after the separation is finished, pouring the waste materials in the ash frying hopper into a material storage tank of the ash frying machine; and the waste is cooled by using a mode of indirectly cooling the storage tank by using clear water, the whole process is kept in a semi-closed state, and cooling water is recycled.
c. Screening: screening the waste in the storage tank, wherein large-particle waste residues enter a waste treatment process for further cooling, stirring and separating; and treating the small-particle waste residues as solid wastes.
The design of the ash frying step further recycles the waste aluminum in the waste slag generated in the smelting process, thereby improving the recycling rate of the waste aluminum.
Example 2: an aluminum bar manufacturing process, as shown in fig. 1 and 2, is a more preferred embodiment based on example 1, and the difference between this embodiment and example 1 is that, in step s10, the detecting package includes the following steps:
alkali washing: the test article is put into an alkaline washing tank for soaking treatment, the surface of the test article can be brightened through an alkaline washing process, the component of a tank liquid is sodium hydroxide, the sodium hydroxide and water are prepared, the concentration of the alkaline solution is controlled to be 14% -16%, the alkaline washing temperature is kept at room temperature, and the time is 5-10 minutes.
Acid washing: because the surface of the test article is alkaline, the hanging ash and the residual alkali liquor can be thoroughly removed after the test article is neutralized by acid, so that a bright basic metal surface is exposed, and the test article is prepared for subsequent detection. The method is characterized in that nitric acid with the concentration of 60% is pumped into a pickling tank by a metering pump for preparation, the concentration of the prepared nitric acid is controlled to be 18% -20%, the temperature in the pickling process is controlled to be room temperature, and the time is 3 minutes. The waste acid produced in this step is recycled to the collected scrap and the aluminium is recovered in solution.
Flushing: and (4) putting the pickled test product into a water washing tank for washing to remove the acid liquor on the surface of the test product, and keeping the washing at room temperature for three minutes.
And fourthly, detection: and detecting the test product by adopting a visual method or an enlarged mirror within 20 times, enabling the qualified product to enter the next detection procedure, and returning the unqualified product to the smelting furnace for reuse after the unqualified product is sawed into sections.
The embodiment brightens and brightens the surface of the test article through the alkali washing process, and the surface of the test article can be thoroughly removed with the hanging ash and the residual alkali liquor after being neutralized by acid, so that the bright basic metal surface is exposed, the influence of the residue on the surface of the test article on the detection result is eliminated, the manual detection is facilitated, and the accuracy of the manual detection is improved.
Example 3: an aluminum bar manufacturing process, as shown in fig. 1 and 3, is a more preferred embodiment based on example 2, and the difference between this embodiment and example 2 is that, in step s10, the detecting package includes the following steps:
alkali washing: the test article is put into an alkaline washing tank for soaking treatment, the surface of the test article can be brightened through an alkaline washing process, the component of a tank liquid is sodium hydroxide, the sodium hydroxide and water are prepared, the concentration of the alkaline solution is controlled to be 14% -16%, the alkaline washing temperature is kept at room temperature, and the time is 5-10 minutes.
Acid washing: because the surface of the test article is alkaline, the hanging ash and the residual alkali liquor can be thoroughly removed after the test article is neutralized by acid, so that a bright basic metal surface is exposed, and the test article is prepared for subsequent detection. The method is characterized in that nitric acid with the concentration of 60% is pumped into a pickling tank by a metering pump for preparation, the concentration of the prepared nitric acid is controlled to be 18% -20%, the temperature in the pickling process is controlled to be room temperature, and the time is 3 minutes. The waste acid produced in this step is recycled to the collected scrap and the aluminium is recovered in solution.
Flushing: and (4) putting the pickled test product into a water washing tank for washing to remove the acid liquor on the surface of the test product, and keeping the washing at room temperature for three minutes.
Fourthly, preliminary detection: and detecting the test product by adopting a visual method or an enlarged mirror within 20 times, enabling the qualified product to enter the next detection procedure, and returning the unqualified product to the smelting furnace for reuse after the unqualified product is sawed into sections.
Mixed pickling: the project uses a metering pump to pump nitric acid, hydrofluoric acid and hydrochloric acid into a pickling tank for preparation, and the preparation proportion is hydrofluoric acid: hydrochloric acid: nitric acid = 1: 5: 15, controlling the temperature in the mixed pickling process to be room temperature for 5-10 minutes. The waste acid produced in this step is recycled to the collected scrap and the aluminium is recovered in solution.
Sixthly, flushing: and (4) putting the test product subjected to mixed acid washing into a water washing tank for washing to remove the acid liquor on the surface of the test product, and keeping the temperature of the washing at room temperature for three minutes.
And (c) secondary detection: and (3) detecting the test product by adopting a metallographic microscope, feeding the qualified product into a finished product warehouse, and returning the unqualified product to the smelting furnace for reuse after the unqualified product is sawed into sections.
This embodiment is through on the basis that visual method detected, utilizes mixed acid to clear away the oxide layer that produces on the test article surface in the testing process to eliminate test article surface part metal, so that operating personnel observes the crystalline grain of test article and judges whether qualified test article, has realized the detection to higher qualified requirement, is favorable to promoting the competitiveness of product.
The above description is only a preferred embodiment of the present invention, and the protection scope of the present invention is not limited to the above embodiments, and all technical solutions belonging to the idea of the present invention belong to the protection scope of the present invention. It should be noted that modifications and embellishments within the scope of the invention may occur to those skilled in the art without departing from the principle of the invention, and are considered to be within the scope of the invention.
Claims (9)
1. The aluminum bar manufacturing process is characterized by comprising the following steps:
s1, smelting preparation: designing the proportion of raw materials according to the characteristics of products, directly adding aluminum ingots, magnesium ingots and waste aluminum without coatings into a heat accumulating type natural gas smelting furnace by a forklift, wherein the mass of the waste aluminum accounts for 5-10% of the total weight of the raw materials;
s2, primary smelting: smelting: after the raw materials are added, closing a furnace door, controlling the temperature of a hearth to be 1200 +/-15 ℃, and maintaining the temperature of a furnace body to be 900 +/-15 ℃; simultaneously, carrying out electromagnetic stirring on the aluminum melt; after the materials are in a liquid state, opening a furnace door, adding magnesium ingots, alloy additives and slag-forming agents, closing the furnace door, and continuing stirring until the materials are completely melted; skimming: in the stirring process, skimming is carried out when the thickness of the floating waste residue is more than 5mm, and 40-50% of the waste residue is skimming;
s3, refining: after the aluminum liquid is completely melted, guiding the aluminum liquid in the furnace from a closed diversion trench above the smelting furnace to a heat accumulating type natural gas heat preservation furnace for refining; the temperature of the holding furnace is kept at 700-760 ℃; meanwhile, impurities and bubbles in the aluminum liquid are removed in a mode of adding a slagging agent, a refining agent and filling nitrogen, and the nitrogen supply speed is 150 and 160m during the dry distillation/h; skimming is not carried out periodically, and the skimming principle is the same as that of the skimming step in the step S2;
s4, degassing and filtering: firstly, introducing nitrogen from the bottom of the heat preservation furnace through an online processing device, stirring and smashing the nitrogen into small bubbles by a graphite rotor, gradually enlarging the small bubbles when the small bubbles rise, and converting hydrogen atoms in the aluminum liquid into hydrogen and then bringing the hydrogen atoms to the surface of the aluminum liquid for combustion; then guiding the slag-containing aluminum liquid on the surface layer from an overflow port of the holding furnace to an online treatment device, and filtering the waste slag through a filtering device of an online treatment facility;
s5, sampling analysis: sampling at the furnace door of the heat preservation furnace, detecting the components of the heat preservation furnace, and continuously adding aluminum ingots and magnesium ingots into unqualified aluminum liquid until the aluminum liquid meets the requirements;
s6, standing and forming: standing and forming the qualified filtrate in a furnace;
s7, grain refinement: conveying the aluminum liquid in the heat preservation furnace into casting equipment through a closed guide groove, and arranging a wire feeder at the front end of the guide groove to continuously feed aluminum, titanium and boron into the conveyed aluminum liquid;
s8, vertical shaft casting: guiding the refined aluminum liquid into a feed chute of the cast rod mold from the closed guide chute for online treatment, cooling, gradually turning the aluminum liquid into softened aluminum alloy, slowly extruding from the mold, and solidifying and molding;
s9, sawing: conveying the aluminum bar to an automatic bar sawing machine by using a forklift, and sawing by using a water jet cutter;
s10, detecting and packaging: sampling the sawed aluminum bar, detecting a section of the sawed sample with the thickness of 0.3-0.4cm, and returning a product which is unqualified in detection result to the smelting furnace for reuse after all the products are sawed into sections;
also comprises the ash frying step:
a. stirring and separating: guiding the waste residues generated in the steps S2 and S3 into an ash frying machine for stirring, and adding clear water during stirring; stirring for 8-10min to see the gradual blackening of the aluminum ash surface in the pan of the ash frying machine, wherein the aluminum water with high specific gravity sinks to the pan bottom and flows out along the holes of the pan bottom, and finally enters a smelting furnace for reuse; the ash with low specific gravity is suspended on the surface of the upper end of the pot to complete the separation.
2. The process for manufacturing the aluminum bar as claimed in claim 1, wherein in the ash frying step, when the aluminum liquid is agglomerated in the stirring process, the stirring blades are rotated in a positive and negative cross manner to break up the agglomerates.
3. The aluminum bar manufacturing process of claim 1, wherein the ash frying step further comprises the steps of:
b. waste treatment: after the separation is finished, the waste materials in the ash frying hopper are poured into a material storage tank of the ash frying machine, and the waste materials are indirectly cooled by clear water and are kept in a semi-closed state in the whole process;
c. screening: screening large-particle waste residues in a storage tank, and then sending the large-particle waste residues into a waste treatment process for further cooling, stirring and separating; and treating the residual small-particle waste residues as solid wastes.
4. The process of claim 1, wherein in step S1, the surface of the recycled aluminum scrap is polished, and the scrap on the surface of the aluminum scrap is sucked clean after polishing.
5. The process of claim 1, wherein in step S8, talc powder for lubrication is applied to the mold during the processing.
6. The aluminum bar manufacturing process of claim 1, wherein in the step S9, leftover bits and pieces left after sawing are sent to a smelting furnace for reuse.
7. The aluminum bar manufacturing process of claim 1, wherein in the step S10, the detection method is as follows: alkali washing: putting the test article into an alkaline washing tank for soaking treatment, wherein the component of the tank liquid is preferably a sodium hydroxide solution with the concentration of 14-16%, and the alkaline washing temperature is kept at room temperature for 5-10 minutes; acid washing: cleaning the test article by using nitric acid with the concentration of 18% -20%; flushing: the test product after the acid washing enters a water washing tank for washing, and the washing is carried out for three minutes while the room temperature is maintained; and fourthly, detection: and detecting the test product by adopting a visual method or an enlarged mirror within 20 times, and returning the unqualified product to the smelting furnace for reuse after the product is sawed into sections.
8. The aluminum bar manufacturing process according to claim 1, wherein in step S10, another preferred detection method is as follows: alkali washing: putting the test article into an alkaline washing tank for soaking treatment, wherein the component of the tank liquid is preferably a sodium hydroxide solution with the concentration of 14-16%, and the alkaline washing temperature is kept at room temperature for 5-10 minutes; acid washing: cleaning the test article by using nitric acid with the concentration of 18% -20%, and removing hanging ash and residual alkali liquor; flushing: the test product after the acid washing enters a water washing tank for washing, and the washing is carried out for three minutes while the room temperature is maintained; and fourthly, detection: detecting the test product by adopting a visual method or an enlarged mirror within 20 times, feeding the qualified product into the next detection procedure, and returning the unqualified product to the smelting furnace for reuse after the unqualified product is sawed into sections; mixed pickling: adding nitric acid, hydrofluoric acid and hydrochloric acid into a pickling tank by using a metering pump for preparation, wherein the preparation ratio is hydrofluoric acid: hydrochloric acid: nitric acid = 1: 5: 15, controlling the temperature in the mixed pickling process to be room temperature for 5-10 minutes.
9. The process of claim 7 or 8, wherein in step S1, the recycled waste aluminum surface is ground before charging, the scrap on the waste aluminum surface is sucked and collected after grinding, and the waste acid generated in step S10 is reused in the collected scrap to recycle the aluminum in the scrap in the form of solution.
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