CN112708789A - Method for efficiently producing high-strength cast aluminum alloy - Google Patents
Method for efficiently producing high-strength cast aluminum alloy Download PDFInfo
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- CN112708789A CN112708789A CN202011529330.1A CN202011529330A CN112708789A CN 112708789 A CN112708789 A CN 112708789A CN 202011529330 A CN202011529330 A CN 202011529330A CN 112708789 A CN112708789 A CN 112708789A
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- C22C1/00—Making non-ferrous alloys
- C22C1/02—Making non-ferrous alloys by melting
- C22C1/026—Alloys based on aluminium
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- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
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- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D11/00—Continuous casting of metals, i.e. casting in indefinite lengths
- B22D11/04—Continuous casting of metals, i.e. casting in indefinite lengths into open-ended moulds
- B22D11/045—Continuous casting of metals, i.e. casting in indefinite lengths into open-ended moulds for horizontal 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
- B22D11/00—Continuous casting of metals, i.e. casting in indefinite lengths
- B22D11/16—Controlling or regulating processes or operations
- B22D11/22—Controlling or regulating processes or operations for cooling cast stock or mould
- B22D11/225—Controlling or regulating processes or operations for cooling cast stock or mould for secondary cooling
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
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- 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 discloses a method for efficiently producing high-strength cast aluminum alloy, which comprises the following steps: firstly, preparing an aluminum alloy solution by vacuum in-ladle alloying; secondly, refining, standing and slagging off the aluminum alloy melt in a low-level furnace by using a refining agent to prepare the aluminum alloy melt to be poured; and step three, casting the aluminum alloy solution to obtain an aluminum alloy ingot. The invention saves the natural gas heating energy required by the preheating of the high-level furnace and the heating alloying after the aluminum is added, thereby greatly reducing the production energy consumption; compared with the existing aluminum alloy production process, the production time of one furnace is optimized from about 5 hours to about 3 hours, so that the production efficiency is greatly improved; the raw material and labor cost are reduced; the cast tensile strength of the A356 cast aluminum alloy produced by the process is averagely improved by more than 10 percent; the tensile strength of the T6 state is close to 300MPa, and the elongation is more than 8%; the low-power pinhole degree 1 grade rate is more than 98 percent.
Description
The technical field is as follows:
the invention relates to a method for producing cast aluminum alloy, in particular to a method for efficiently producing high-strength cast aluminum alloy.
Background art:
the production process of the existing cast aluminum alloy ingot generally comprises the process steps of preparing the components of the aluminum alloy in a furnace, alloying, adding a refining agent for refining, slagging off, casting and the like. The prior production process for casting aluminum alloy ingots has the problems of high energy consumption, large heat loss, high casting loss, low production efficiency and the like. Taking A356 cast aluminum alloy as an example, the production process comprises the following steps: adding metallic silicon into a high-level furnace, flatly paving the metallic silicon at the bottom of the furnace, heating the furnace to bake and preheat the metallic silicon, pouring high-temperature primary aluminum liquid into the furnace by a vacuum bag, adding a titanium agent at an aluminum pouring furnace mouth, flushing the titanium agent into the furnace by using the primary aluminum liquid to alloy elements, stewing for a period of time, skimming slag, and primarily skimming scum on the surface of the aluminum liquid; drilling a hole in the high-position furnace, pouring molten aluminum in the high-position furnace into the low-position furnace, placing a magnesium ingot in the flowing molten aluminum in the aluminum pouring process, and melting the magnesium ingot to the low-position furnace by utilizing the high-temperature flowing molten aluminum; after the furnace is turned over, refining in a low-level furnace, uniformly blowing a refining agent into the molten aluminum by using the five thousandth of the refining agent corresponding to the weight of the molten aluminum and matching with refining gas (nitrogen or argon), taking out hydrogen and slag in the molten aluminum, and gradually forming a layer of separable scum on the surface of the molten aluminum, wherein the general refining time is 40 minutes; slagging off is carried out after refining is finished, and casting of A356 aluminum alloy can not be carried out until no floating slag such as a mirror surface exists on the surface of the aluminum liquid; the launder, the filter plate of the filter box and the casting machine mould are fully baked and dried before casting, and then the low-level furnace is opened for production and casting. The whole casting production process takes about 5 hours from the beginning of silicon feeding to the completion of casting, and the casting production process flow of the A356 aluminum alloy has the following defects:
(1) the preheating of the metal silicon and the baking in the furnace need to have certain hearth temperature in the furnace, the baking of the metal silicon needs to continuously raise the temperature for the smelting furnace to keep constant temperature in the furnace, and the production energy consumption is increased.
(2) The temperature of the aluminum liquid in the vacuum bag is reduced to about 800 ℃ after the aluminum liquid is poured into the high-position furnace, compared with the original aluminum liquid which is just pumped and has the temperature of 940 ℃, the aluminum liquid wastes more than 100 ℃ in the processes of transportation and furnace reversing, and the heat loss is high;
(3) the silicon melting time in the high-position furnace is longer, the average time of each furnace is more than 180 minutes, the temperature required for completely dissolving the metal silicon by the aluminum reaches more than 700 ℃, the temperature of the aluminum liquid in the vacuum bag is reduced to about 800 ℃ after the aluminum liquid is poured into the high-position furnace, the heat of the original aluminum liquid is continuously dissipated in the silicon melting process, and the temperature requirement in the long-time silicon melting process cannot be met, so that the high-position furnace needs to be heated, the reaction temperature is maintained, and the production energy consumption is further increased;
(4) because the temperature loss in the converter process is large, the temperature of the fused gold melt converter is not controlled, the refining temperature in the refining process is low, the viscosity of the aluminum alloy melt is increased, the slag-aluminum separation difficulty is large, and the slag removal capability is insufficient; in addition, the prior refining process does not accurately control the refining rate, and the refining effect is poor.
(5) The vacuum ladle conveying of the primary aluminum liquid and the silicon melting alloying are carried out step by step, and the two process steps are long in time consumption, so that the whole casting production process is long in time consumption and low in production efficiency.
(6) The homogenization of the components of the molten aluminum alloy depends on the granularity of the metal silicon, the grade of the metal silicon used for most aluminum alloy ingot casting production is 441, the granularity of the metal silicon is 50-150 mm, the contact area between the large metal silicon particles and the aluminum liquid is reduced, the reaction time is increased, the silicon molecules are uniformly diffused into the molten aluminum body and are alloyed for about 120min, the silicon melting time is long, the average time of each furnace is more than 180min, and the production efficiency is low.
(7) And 1.8 percent of original casting loss is caused in the process of heating up the high-level furnace for melting silicon and slagging off for a long time.
(8) The sequential solidification state is that the gas is gradually cooled from the bottom to the top and from two sides to the middle, so that the gas is discharged to the top, and when a horizontal casting machine is adopted for casting at present, the water inflow of cooling water in a region 1 is the same as that of cooling water in a region 2, so that the water level of the cooling water in the region 1 is as high as that of the cooling water in the region 2, the cooling strength of two sides is high, the middle is easy to solidify, the sequential solidification is difficult to realize, and thus the gas is difficult to discharge in the process of solidification from the bottom to the top; the T6-state tensile strength of the aluminum-silicon alloy cast ingot produced by the prior method is generally about 200MPa, the elongation is about 8 percent, the tensile strength is about 150MPa, the low-power pinhole degree 1 grade rate is 10 percent, and the comprehensive mechanical property is poor.
The invention content is as follows:
in order to solve the problems, the invention aims to provide a method for efficiently producing high-strength cast aluminum alloy with low energy consumption.
The purpose of the invention is implemented by the following technical scheme: a method for efficiently producing a high-strength cast aluminum alloy, comprising the steps of:
firstly, preparing an aluminum alloy solution by vacuum in-ladle alloying;
secondly, refining, standing and slagging off the aluminum alloy melt in a low-level furnace by using a refining agent to prepare the aluminum alloy melt to be poured;
and step three, casting the aluminum alloy solution to be cast by a horizontal casting machine to obtain an aluminum alloy ingot, wherein the casting process parameters are controlled as follows: controlling the casting speed at 13-14 HZ; the flow rate of the aluminum alloy solution to be cast is 2kg/s-3 kg/s; the casting temperature is 60-80 ℃ higher than the liquidus line of the aluminum alloy; the temperature of the cooling water in the first zone is 22-30 ℃, and the flow of the cooling water in the first zone is 7-7.5m3The cooling time of the first zone is 10-15 s; the temperature of the cooling water in the second zone is 22-30 ℃, and the flow of the cooling water in the second zone is 5m3/h-5.5m3The cooling time of the second zone is 10-15 s.
Further, a step of pouring aluminum through a high-position furnace is included between the first step and the second step, an aluminum alloy solution is poured into the high-position furnace and is directly led into the low-position furnace through a furnace eye of the high-position furnace, and in the process of pouring the aluminum alloy solution, the aluminum alloy solution is washed and melts the alloying element ingot added in the pouring aluminum launder.
Further, the first step of preparing the aluminum alloy solution by vacuum in-ladle alloying comprises the following steps: (1) transporting the high-temperature primary aluminum liquid to preheat the vacuum bag; (2) preheating alloying elements by using the preheated vacuum bag; (3) and injecting high-temperature primary aluminum liquid into the vacuum ladle, and completing alloying of aluminum and alloying elements during the period of transporting the vacuum ladle to a casting area after the vacuum ladle is subjected to aluminum pumping to prepare the aluminum alloy solution.
Further, the step (1) of transporting the high-temperature primary aluminum liquid preheating vacuum bag: pumping high-temperature primary aluminum liquid into the vacuum bag through the electrolysis workshop, transporting the vacuum bag to the casting workshop for pouring aluminum, and preheating the vacuum bag by using the high-temperature primary aluminum liquid to ensure that the temperature of a furnace chamber in the vacuum bag reaches 600-.
Further, in the step (1), the high-temperature raw aluminum liquid with the temperature of more than 900 ℃ needs to be transported at least twice to finish preheating of the vacuum bag.
Further, the step (2) preheats the alloying elements by using the preheated vacuum bag: and opening a manhole cover at the top of the preheated vacuum bag, adding the screened alloying elements, closing the manhole cover, sealing the vacuum bag, preserving heat for 15-20 minutes, and fully preheating the alloying elements by utilizing the waste heat of the vacuum bag.
Further, injecting high-temperature primary aluminum liquid into the vacuum bag to complete alloying of aluminum and alloying elements: extracting the primary aluminum liquid with the temperature of above 920 ℃ and injecting the primary aluminum liquid into a vacuum bag, transporting the vacuum bag to a casting area after the vacuum bag is subjected to aluminum extraction, and completing alloying of aluminum and alloying elements in the vacuum bag during the period, wherein the reaction time is 20-40 minutes, and preparing the aluminum alloy solution.
Further, when the cast aluminum alloy is A356 cast aluminum alloy, the alloying elements added in the vacuum bag are metal silicon particles and titanium agent, the particle size of the metal silicon particles is 20-100mm, the titanium agent is buried in the middle of the metal silicon particles and is added into the vacuum bag through a manhole of the vacuum bag, the titanium agent is blocky, and the particle size is more than 20 mm; and the alloying element added into the aluminum pouring chute is a magnesium ingot.
Further, in the second step, secondary refining is adopted for refining, and the specific method comprises the following steps:
the first refining uses inert gas to blow a refining agent, the refining temperature is 90-110 ℃ above the alloy liquidus, and 2-4 kg of the refining agent is added into every 1000 kg of alloy liquid; when the dosage of the refining agent is more than 15kg, the refining rate is controlled to be 0.4-0.5 min/kg; the dosage of the refining agent is less than 15kg, and the refining time is not less than 10 min;
the secondary refining temperature is 70-90 ℃ above the alloy liquid phase line, and the secondary refining temperature is kept still and slag is removed after inert gas is used for blowing for 20 min.
Interpretation of terms:
refining rate: blowing time per kg of refining agent;
casting speed: speed of travel of the mold on the casting line.
The invention has the advantages that:
(1) according to the invention, the vacuum bag is preheated by utilizing the high-temperature molten electrolytic primary aluminum liquid, then the alloying element is put into the vacuum bag, the residual heat of the high-temperature molten primary aluminum liquid in the vacuum bag is utilized to preheat the alloying element, and the high-temperature molten electrolytic primary aluminum liquid is utilized to melt the alloying element in the vacuum bag, so that the residual heat of the vacuum bag and the heat energy of the electrolytic primary aluminum liquid are fully utilized, alloying is completed in the vacuum bag, natural gas heating energy required by heating and alloying after preheating and aluminum feeding of a high-level furnace is saved, and the production energy consumption is greatly reduced;
(2) the high-temperature molten aluminum reacts with alloying elements in the vacuum bag for alloying, compared with the prior art, the heat loss of the high-temperature molten aluminum in the conveying process is fully utilized, the reaction temperature requirement in the alloying process can be met, and the energy consumption is further reduced;
(3) according to the invention, after alloying elements are added into the vacuum bag, the vacuum bag is transported to the electrolytic bath to finish roasting of the alloying elements, and after aluminum is pumped out, the vacuum bag is transported to the casting high-level furnace to finish melting alloying of the alloying elements in aluminum liquid.
(4) The invention avoids secondary heating, can effectively reduce the burning loss in the silicon melting process, can directly refine the obtained alloy liquid, and simultaneously adopts a secondary refining process, wherein the primary refining mainly removes slag, the secondary refining mainly removes gas, and simultaneously controls the refining speed, so that a more ideal gas and slag removing effect can be achieved, the hydrogen removing rate can reach 70%, and the slag removing rate can reach 90%; when the slag is removed after refining, the slag-aluminum separation effect is good, less aluminum is brought out in the slag removing process, and the original casting loss is comprehensively reduced by nearly 0.5%.
(5) According to the invention, the water level of the cooling water in the first area is higher than that of the cooling water in the second area by increasing the flow of the cooling water in the first area, the cooling strength of the two sides is reduced in the cooling process of the second area, and the solidification in the middle is slow, so that the alloy melt can be sequentially solidified, and therefore, gas can be smoothly discharged from the bottom to the top in the solidification process, the feeding capacity is enhanced, and the mechanical property of the alloy is further improved; the cast tensile strength of the aluminum-silicon cast aluminum alloy produced by the process is averagely improved by more than 10 percent; the tensile strength of the T6 state is close to 300MPa, and the elongation is more than 8%; the low-power pinhole degree 1 grade rate is more than 98 percent.
Drawings
FIG. 1 is a flow chart of the production process of the aluminum alloy of example 1A 356.
The specific implementation mode is as follows:
example 1: this example further illustrates a method for efficiently producing a high strength cast aluminum alloy, using an a356 aluminum alloy as an example. The method specifically comprises the following steps:
(1) pumping primary aluminum liquid into a 6-ton vacuum bag through an electrolysis workshop, transporting the primary aluminum liquid to a casting workshop for aluminum pouring, preheating the vacuum bag by using high-temperature primary aluminum liquid with the temperature of over 900 ℃, wherein the temperature of a furnace chamber in the vacuum bag reaches 600 plus 700 ℃ after two preheating processes, and the condition of adding silicon and titanium is met.
(2) 450kg of metal silicon with the particle size of 20-100mm is screened and put into a bag.
(3) 12kg of titanium agent was embedded in the metal silicon and subsequently poured into a vacuum bag together with the metal silicon. The titanium agent is buried among the metal silicon, so that the combustion of the titanium agent combustion improver can be effectively reduced, if the titanium agent is firstly added to the bottom of the vacuum ladle or is then added to the metal silicon, the titanium agent combustion improver is firstly combusted in the vacuum ladle, more melting time is needed for melting the titanium after aluminum pumping, and the actual yield is lower.
(3) And (4) hoisting the fully preheated vacuum bag to a vacuum bag seat by using a crane, and opening a manhole cover at the top of the vacuum bag.
(4) A crown block lifts the bag filled with the silicon metal and the titanium metal to the position above a manhole of the vacuum bag, the bottom of the bag is boiled by high temperature in the manhole, and the silicon metal and the titanium metal naturally fall into the vacuum bag; then, the asbestos rope of the manhole sealing ring is replaced, a circle of asbestos mud is smeared, the airtightness of the vacuum bag is guaranteed, and the manhole cover is closed.
(5) And (4) keeping the temperature of the sealed vacuum bag for 15-20 minutes to ensure that the metal silicon is fully preheated by utilizing the waste heat of the vacuum bag.
(6) A crown block hoists the vacuum bag after the silicon-titanium heat preservation to an electrolytic bath for aluminum pumping; the aluminum extraction port is inserted into the electrolytic cell, and 5900kg of primary aluminum liquid is extracted. Wherein, the selection standard of the electrolytic cell is as follows: the tank condition is good and the operation is stable; the bottom sediment is less, and the bottom pressure drop is less than or equal to 350 mV; the lower level is more than or equal to 19 cm; the temperature of the electrolytic aluminum liquid is above 920 ℃;
(7) and after the vacuum ladle aluminum pumping is finished, transporting the vacuum ladle aluminum to a casting area, and during the period, carrying out alloying reaction on the metal silicon, the titanium agent and the aluminum melt for 20-40 minutes to prepare the aluminum alloy melt. In the prior art, primary aluminum liquid is extracted from a vacuum bag, the temperature of the primary aluminum liquid is only 820 plus 850 ℃ when the primary aluminum liquid is transported to a casting area, the temperature of the aluminum liquid can be reduced greatly after the primary aluminum liquid is poured into a furnace, so that metal silicon in the furnace needs to be baked and preheated in advance, 30-60 minutes is needed for fully preheating 1.3 tons of metal silicon in the furnace, and then three vacuum bags filled with the primary aluminum liquid are poured into the furnace in sequence; the high-level furnace is a natural gas furnace or a resistance furnace, the temperature rise rate is slow and is increased to 700-750 ℃ at most, so the temperature of the solution in the furnace is not high, the unscreened granularity of the silicon blocks is larger, and 60-120 minutes is needed for completely alloying 1.3 tons of metal silicon in the furnace. In the process, the silicon briquette has small granularity after screening, the heat transfer is fast, the metal silicon amount in each vacuum bag is small, and the preheating only needs 15 to 20 minutes. In the process, the metal silicon is in a vacuum bag, the molten metal silicon is high-temperature aluminum liquid with the temperature of over 900 ℃ in the electrolytic cell, and the aluminum liquid drives the metal silicon to have a certain stirring and scouring effect when the aluminum liquid is pumped in, so that the metal silicon is more favorable for quick melting, and the melting alloying time is 20-40 minutes.
(8) Pouring the aluminum alloy solution into a high-position furnace, directly guiding the aluminum alloy solution into a low-position furnace through a furnace eye of the high-position furnace, and in the process of furnace pouring, washing and melting 63kg of magnesium ingots added in an aluminum pouring launder by the aluminum alloy solution.
(9) Refining the aluminum alloy solution in a low-level furnace by using a refining agent, standing, and slagging off to prepare an aluminum alloy solution to be poured;
in the embodiment, secondary refining is adopted for refining, and the specific method comprises the following steps:
the refining agent is blown by inert gas in the first refining; the refining temperature is 90-110 ℃ above the liquidus line of the alloy, and the refining temperature of the A356 aluminum alloy in the embodiment is 710-730 ℃; 2-4 kg of refining agent is added into every 1000 kg of alloy liquid, and 18 kg of refining agent is added in the embodiment; the refining rate is controlled at 0.4-0.5 min/kg;
the secondary refining temperature is 70-90 ℃ above the liquidus line of the alloy, and the A356 aluminum alloy refining temperature of the embodiment is 690-710 ℃; blowing inert gas for 20min, standing, and removing slag. The inert gas used in this example was nitrogen and the refining agent was a chloride refining agent. The chlorine salt refining agent comprises the following components in percentage by weight: 3 percent of magnesium carbonate, 3 percent of calcium fluoride, 3 percent of potassium hexafluoroaluminate, 21 percent of cryolite and aluminum fluoride, 70 percent of natural carnallite, and the sum of the mass percentages of the components is 100 percent. Wherein the mass ratio of the cryolite to the aluminum fluoride is 66: 34. The mass percentage of free water in the natural carnallite is not more than 1 percent, and the mass percentage of magnesium chloride is less than 40 percent. The natural carnallite is obtained by crushing, roasting, detecting and analyzing natural carnallite mineral raw materials. Through detection, the natural carnallite contains components such as sodium chloride and the like besides magnesium chloride and potassium chloride. The purity of the magnesium carbonate, the calcium fluoride, the potassium hexafluoroaluminate, the cryolite and the aluminum fluoride is higher than 95 percent, free water is not contained, and the mass percentage of water is not higher than 0.5 percent.
(10) And (4) after removing hydrogen and slag, allowing the aluminum alloy solution to flow into a horizontal casting machine for casting to obtain an A356 alloy ingot. The specific process steps are as follows:
1. baking the chute for 180-210 min in advance, and maintaining the chute before baking;
2. cleaning the talcum powder in the chute, beating off the suspended talcum powder on the surface after the cast aluminum water is stable, adding an asbestos plate for sealing and covering, and preheating the filter plate in advance;
3. opening a cooling water valve;
4. temperature of the die: 130 ℃ and 180 ℃;
the stable post-casting process parameters are controlled as follows: controlling the casting speed at 13-14 Hz; the flow rate of the aluminum alloy solution to be cast is 2kg/s-3 kg/s; the casting temperature is 680-700 ℃; the temperature of the cooling water in the first zone is 22-30 ℃, and the flow of the cooling water in the first zone is 7-7.5m3The cooling time of the first zone is 10-15 s; the temperature of the cooling water in the second zone is 22-30 ℃, and the flow of the cooling water in the second zone is 5m3/h-5.5m3The cooling time of the second zone is 10-15 s.
The A356 alloy ingot prepared by the method of the embodiment has the tensile strength of 187MPa through testing; the tensile strength in the T6 state is 293MPa, and the elongation is 10%; the low-power pinhole degree 1 grade rate is 98 percent.
In the embodiment, the high-temperature molten electrolytic primary aluminum liquid is used for melting the metallic silicon and the titanium agent in the vacuum bag, the waste heat of the vacuum bag and the temperature of the electrolytic primary aluminum liquid are used, the time for baking and melting silicon in the original furnace is shortened, and the metallic silicon and the titanium agent completely melt the metallic silicon and the titanium required by the A356 aluminum alloy in the process of transporting the vacuum bag; according to the test result, the temperature of the solution in the vacuum bag can reach more than 750 ℃, so the solution in the vacuum bag does not need to be insulated and smelted after being poured into the high-level furnace, and is directly introduced into the low-level furnace, and magnesium ingots are added in the aluminum pouring process to be melted in the aluminum liquid, and the solution finishes the preparation of the A356 aluminum alloy. Refining, standing, slagging off and casting in a low-position furnace.
The method is characterized in that the technological process of silicon drying, silicon melting and titanium flushing of the blast furnace is changed into the mode of silicon melting and titanium melting in the vacuum ladle, silicon titanium is added into the vacuum ladle and then is transported to the electrolytic cell to finish the baking of metal silicon, and the vacuum ladle is used for transporting the vacuum ladle to the casting blast furnace after aluminum pumping to finish the melting alloying of the silicon titanium in aluminum liquid.
The energy-saving method has the advantages that the waste heat in the vacuum bag and the heat of high-temperature primary aluminum liquid are completely utilized, the A356 alloy is smelted in the vacuum bag by means of the heat preservation performance of the vacuum bag, and the natural gas heating energy of the high-position furnace for drying silicon and heating and melting silicon after aluminum is added is saved.
Through tests, the practical yield of silicon of the vacuum-packaged silicon titanium melt is 97.28%, the practical yield of titanium is 81.63%, and the practical yield of titanium is higher than the casting practical yield of the conventional production process at present; in addition, secondary heating is avoided, burning loss in the silicon melting process can be effectively reduced, the obtained alloy liquid can be directly refined, meanwhile, when the refining agent is used for slagging off after refining, the slag-aluminum separation effect is good, less aluminum is brought out in the slagging off process, and the original casting loss is comprehensively reduced by 0.5%.
Compared with the aluminum-silicon alloy sample prepared by the conventional silicon melting process, the aluminum-silicon alloy sample prepared by the embodiment has the advantages that alpha-Al dendrite distribution is uniform and the generation is small, because eutectic silicon particles are fine and the roundness of silicon is large in a vacuum bag due to the high temperature of silicon melting; when high-temperature primary aluminum liquid is pumped into the vacuum bag, the aluminum liquid has certain scouring force, the segregation degree in the process of melting silicon is smaller, and the primary silicon is less.
In the embodiment, high-temperature primary aluminum liquid is injected into the vacuum bag, and Si obtains enough kinetic energy from molten aluminum under the impact stirring action of the high-temperature primary aluminum liquid, so that the thermal shock of silicon molecules is intensified, the constraint of other surrounding molecules on the silicon molecules can be eliminated, the silicon molecules are dissolved and diffused into a molten aluminum body, and the silicon molecules are diffused from a high-concentration area to a low-concentration area, so that the segregation is reduced, and the components of the aluminum-silicon alloy are more uniform.
The above description is only for the purpose of illustrating the preferred embodiments of the present invention and is not to be construed as limiting the invention, and any modifications, equivalents, improvements and the like that fall within the spirit and principle of the present invention are intended to be included therein.
Claims (9)
1. A method for efficiently producing a high-strength cast aluminum alloy is characterized by comprising the following steps:
firstly, preparing an aluminum alloy solution by vacuum in-ladle alloying;
secondly, refining, standing and slagging off the aluminum alloy melt in a low-level furnace by using a refining agent to prepare the aluminum alloy melt to be poured;
and step three, casting the aluminum alloy solution to be cast by a horizontal casting machine to obtain an aluminum alloy ingot, wherein the casting process parameters are controlled as follows: controlling the casting speed at 13-14 HZ; the flow rate of the aluminum alloy solution to be cast is 2kg/s-3 kg/s; the casting temperature is 60-80 ℃ higher than the liquidus line of the aluminum alloy; the temperature of the cooling water in the first zone is 22-30 ℃, and the flow of the cooling water in the first zone is 7-7.5m3The cooling time of the first zone is 10-15 s; the temperature of the cooling water in the second zone is 22-30 ℃, and the flow of the cooling water in the second zone is 5m3/h-5.5m3The cooling time of the second zone is 10-15 s.
2. The method for efficiently producing high-strength cast aluminum alloy according to claim 1, wherein the step of pouring aluminum through the blast furnace is further included between the first step and the second step, the molten aluminum alloy is poured into the blast furnace and directly introduced into the low furnace through a furnace eye of the blast furnace, and during the step of pouring, the molten aluminum alloy scours and melts the ingot of the alloying elements added into the pouring chute.
3. The method for efficiently producing a high-strength cast aluminum alloy according to claim 1 or 2, wherein the first step of preparing the aluminum alloy solution by vacuum in-ladle alloying comprises the steps of: (1) transporting the high-temperature primary aluminum liquid to preheat the vacuum bag; (2) preheating alloying elements by using the preheated vacuum bag; (3) and injecting high-temperature primary aluminum liquid into the vacuum ladle, and completing alloying of aluminum and alloying elements during the period of transporting the vacuum ladle to a casting area after the vacuum ladle is subjected to aluminum pumping to prepare the aluminum alloy solution.
4. The method for efficiently producing high-strength cast aluminum alloy according to claim 3, wherein the step (1) of transporting the high-temperature primary aluminum liquid preheating vacuum bag: pumping high-temperature primary aluminum liquid into the vacuum bag through the electrolysis workshop, transporting the vacuum bag to the casting workshop for pouring aluminum, and preheating the vacuum bag by using the high-temperature primary aluminum liquid to ensure that the temperature of a furnace chamber in the vacuum bag reaches 600-.
5. The method for efficiently producing high-strength cast aluminum alloy according to claim 4, wherein in the step (1), the high-temperature raw aluminum liquid with the temperature of 900 ℃ or higher is required to be transported at least twice to complete the preheating of the vacuum ladle.
6. A method for efficiently producing a high-strength cast aluminum alloy according to claim 3, wherein the step (2) preheats the alloying elements with the preheated vacuum ladle: and opening a manhole cover at the top of the preheated vacuum bag, adding the screened alloying elements, closing the manhole cover, sealing the vacuum bag, preserving heat for 15-20 minutes, and fully preheating the alloying elements by utilizing the waste heat of the vacuum bag.
7. The method for efficiently producing high-strength cast aluminum alloy according to claim 3, wherein the (3) vacuum bag is filled with high-temperature primary aluminum liquid to complete the alloying of aluminum and alloying elements: extracting the primary aluminum liquid with the temperature of above 920 ℃ and injecting the primary aluminum liquid into a vacuum bag, transporting the vacuum bag to a casting area after the vacuum bag is subjected to aluminum extraction, and completing alloying of aluminum and alloying elements in the vacuum bag during the period, wherein the reaction time is 20-40 minutes, and preparing the aluminum alloy solution.
8. The method for efficiently producing high-strength cast aluminum alloy according to claim 3, wherein when the cast aluminum alloy is A356 cast aluminum alloy, the alloying elements added in the vacuum bag are metallic silicon particles and a titanium agent, the metallic silicon particles have a particle size of 20-100mm, the titanium agent is embedded in the metallic silicon particles and is added into the vacuum bag through a manhole of the vacuum bag, and the titanium agent is blocky and has a particle size of 20mm or more; and the alloying element added into the aluminum pouring chute is a magnesium ingot.
9. The method for efficiently producing the high-strength cast aluminum alloy according to claim 1, wherein in the second step, secondary refining is adopted, and the specific method is as follows:
the first refining uses inert gas to blow a refining agent, the refining temperature is 90-110 ℃ above the alloy liquidus, and 2-4 kg of the refining agent is added into every 1000 kg of alloy liquid; when the dosage of the refining agent is more than 15kg, the refining rate is controlled to be 0.4-0.5 min/kg; the dosage of the refining agent is less than 15kg, and the refining time is not less than 10 min;
the secondary refining temperature is 70-90 ℃ above the alloy liquid phase line, and the secondary refining temperature is kept still and slag is removed after inert gas is used for blowing for 20 min.
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