CN116786774A - Dummy ingot head and method for preventing aluminum leakage bending of aluminum alloy ingot casting facet - Google Patents
Dummy ingot head and method for preventing aluminum leakage bending of aluminum alloy ingot casting facet Download PDFInfo
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- CN116786774A CN116786774A CN202310958835.7A CN202310958835A CN116786774A CN 116786774 A CN116786774 A CN 116786774A CN 202310958835 A CN202310958835 A CN 202310958835A CN 116786774 A CN116786774 A CN 116786774A
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- ingot
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- base
- aluminum alloy
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- 238000005266 casting Methods 0.000 title claims abstract description 54
- 229910000838 Al alloy Inorganic materials 0.000 title claims abstract description 23
- 229910052782 aluminium Inorganic materials 0.000 title claims abstract description 21
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 title claims abstract description 21
- 238000005452 bending Methods 0.000 title claims abstract description 21
- 238000000034 method Methods 0.000 title claims abstract description 18
- 239000000463 material Substances 0.000 claims description 4
- 229910000831 Steel Inorganic materials 0.000 claims description 2
- 239000010959 steel Substances 0.000 claims description 2
- 230000005484 gravity Effects 0.000 abstract description 5
- 230000007547 defect Effects 0.000 abstract description 3
- 208000029152 Small face Diseases 0.000 abstract description 2
- 238000012795 verification Methods 0.000 abstract 1
- 229910045601 alloy Inorganic materials 0.000 description 13
- 239000000956 alloy Substances 0.000 description 13
- 238000004519 manufacturing process Methods 0.000 description 7
- 239000000498 cooling water Substances 0.000 description 5
- 238000010438 heat treatment Methods 0.000 description 5
- 239000000155 melt Substances 0.000 description 5
- 239000000203 mixture Substances 0.000 description 5
- 238000002360 preparation method Methods 0.000 description 5
- 239000007788 liquid Substances 0.000 description 4
- 238000012986 modification Methods 0.000 description 4
- 230000004048 modification Effects 0.000 description 4
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 3
- 238000003723 Smelting Methods 0.000 description 3
- 230000009471 action Effects 0.000 description 3
- 230000008859 change Effects 0.000 description 3
- 238000001035 drying Methods 0.000 description 3
- 239000012535 impurity Substances 0.000 description 3
- 239000004615 ingredient Substances 0.000 description 3
- 238000003801 milling Methods 0.000 description 3
- 238000007670 refining Methods 0.000 description 3
- 230000001105 regulatory effect Effects 0.000 description 3
- 229910052710 silicon Inorganic materials 0.000 description 3
- 239000010703 silicon Substances 0.000 description 3
- 239000002893 slag Substances 0.000 description 3
- 230000006978 adaptation Effects 0.000 description 2
- 230000000052 comparative effect Effects 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- 238000009826 distribution Methods 0.000 description 2
- 230000005496 eutectics Effects 0.000 description 2
- 230000008569 process Effects 0.000 description 2
- 230000009286 beneficial effect Effects 0.000 description 1
- 239000003153 chemical reaction reagent Substances 0.000 description 1
- 238000009749 continuous casting Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000009434 installation Methods 0.000 description 1
- 230000007246 mechanism Effects 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 239000002994 raw material Substances 0.000 description 1
- 238000006467 substitution reaction Methods 0.000 description 1
Classifications
-
- 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
- B22D11/08—Accessories for starting the casting procedure
- B22D11/081—Starter bars
- B22D11/083—Starter bar head; Means for connecting or detaching starter bars and ingots
Abstract
The application discloses a dummy bar head and a method for preventing aluminum leakage bending of an aluminum alloy cast ingot surface, wherein the dummy bar head comprises the following components: a base and a detachable tooling component; when the casting length of the cast aluminum alloy ingot is 300+/-100 mm, warping at two sides of the small face enters a stable stage, and if the warping height difference is greater than 10mm, the detachable tool part is placed at a gap between the base and the warping at two sides, so that the bending of the ingot caused by the movement of the gravity center of the subsequent ingot is prevented. The bending condition of the facets of the flat cast ingot in a casting workshop is improved, and after verification, the bending defect of the cast ingot is reduced by more than 90 percent.
Description
Technical Field
The application relates to the technical field of aluminum alloy casting, in particular to a dummy ingot head and a method for preventing aluminum leakage bending of an aluminum alloy cast ingot facet.
Background
In the casting process of the aluminum alloy, the method comprises an initial stage and a balancing stage, wherein in the initial stage, molten aluminum flows into an ingot casting space formed by a crystallizer and a dummy ingot base through a launder, is rapidly cooled and solidified under the action of cooling water, then the dummy ingot base drops under the traction of a casting machine lifting mechanism to guide the solidified ingot casting to move downwards under the action of a certain preset speed change, the cooling water quantity is also sprayed onto the surface of the ingot casting under the action of a certain preset curve change, meanwhile, the aluminum in the launder is continuously filled, a semi-continuous casting process is formed, and the molten aluminum enters the casting balancing stage after the speed and the cooling water quantity are stable.
In the initial stage, the temperature gradient of the bottom melt metal melt is overlarge, the temperature difference between the two ends and the temperature difference between the center melt are overlarge, and the initial section at the bottom of the cast ingot is solidified, contracted and warped, so that a gap is formed between a small face and a crystallizer, aluminum leakage is easy to occur, and the cast ingot is bent.
If the aluminum leakage of the small surface is found in the current production process, casting can only be continued or casting can be stopped and re-cast. If casting is continued, the cast ingot is easy to bend; after bending, the cast ingot needs to be subjected to facet milling, equipment loss is increased, and cost is increased; if the bending of the small surface of the cast ingot is serious, the cast ingot can only be scrapped, so that the yield is reduced; if the casting is restarted, preparation works such as temperature adjustment, new distribution bag installation, preheating and the like are needed to be carried out on the melt again, so that a great amount of manpower and material resources are wasted.
Disclosure of Invention
In order to solve the defects in the art, the application aims to provide a dummy ingot head and a method for preventing aluminum leakage bending of the aluminum alloy ingot casting surface and improve the bending condition of the flat ingot casting surface in a casting workshop.
According to an aspect of the present application, there is provided a dummy bar head comprising: a base and a detachable tooling component;
wherein when the casting length of the cast aluminum alloy ingot is 300+/-100 mm, the warping of the two sides of the facet enters a stable stage, if the warping height difference is more than 10mm, the detachable tool part is placed at the gap between the base and the warping of the two sides,
according to some embodiments of the application, the surface of the detachable tool part connected with the base is the same as the radian of the base.
According to some embodiments of the application, the face of the detachable tool part, which is connected with the aluminum alloy cast ingot, is provided with a bulge.
According to some embodiments of the application, the protrusions are saw tooth protrusions.
According to some embodiments of the application, the detachable tooling member can withstand a pressure of greater than 15 tons.
According to some embodiments of the application, the detachable tooling member is selected from the group consisting of a steel loop.
According to another aspect of the application, a method for preventing aluminum leakage bending of the small surface of an aluminum alloy ingot is provided, and the aluminum alloy ingot is cast by adopting the dummy ingot head.
According to some embodiments of the application, there is provided: when the casting length of the cast aluminum alloy cast ingot is 300+/-100 mm, warping at two sides of the facet enters a stable stage, and if the warping height difference is greater than 10mm, the detachable tool part is placed at a gap between the base and the warping at two sides;
the lower surface of the detachable tool part is completely attached to the base, and the upper surface completely supports the bent parts on two sides of the cast ingot until casting is finished.
Compared with the prior art, the application at least has the following beneficial effects:
the application provides a dummy bar head, comprising: a base and a detachable tooling component; when the casting length of the cast aluminum alloy ingot is 300+/-100 mm, the warping of the two sides of the facet enters a stable stage, and if the warping height difference is greater than 10mm, the detachable tool part is placed at a gap between the base and the warping of the two sides. The detachable tool part is matched with the base and the warped ingot casting bottom plate, so that sliding is not easy to occur during use; can bear the pressure of the 15t cast ingot without deformation.
The application provides a method for preventing aluminum leakage bending of an aluminum alloy cast ingot surface, which can improve the bending condition of a cast ingot surface in a casting workshop and a flat cast ingot surface, and after the adoption of the method, the bending defect of the cast ingot is reduced by more than 90 percent.
Drawings
Fig. 1 is a schematic view of a dummy bar head according to an exemplary embodiment of the present application.
Fig. 2 is an enlarged schematic view of a detachable tooling member according to an exemplary embodiment of the present application.
Fig. 3 is an ingot diagram prepared according to an exemplary embodiment of the present application.
FIG. 4 is a diagram of an ingot prepared in accordance with a comparative example of the present application.
Detailed Description
The technical solutions of the present application will be clearly and completely described in conjunction with the embodiments of the present application, and it is apparent that the described embodiments are some embodiments of the present application, but not all embodiments. All other embodiments, which can be made by those skilled in the art based on the embodiments of the application without making any inventive effort, are intended to be within the scope of the application.
It is particularly pointed out that similar substitutions and modifications to the application will be apparent to those skilled in the art, which are all deemed to be included in the application. It will be apparent to those skilled in the relevant art that variations and modifications can be made in the methods and applications described herein, or in the appropriate variations and combinations, without departing from the spirit and scope of the application. It will be apparent that the described embodiments are only some, but not all, embodiments of the application.
The application is carried out according to the conventional conditions or the conditions suggested by manufacturers if the specific conditions are not noted, and the raw materials or auxiliary materials and the reagents or instruments are conventional products which can be obtained commercially if the manufacturers are not noted.
The present application will be described in detail below.
In the filling stage of casting, the dummy ingot head stretches into a cavity formed by the crystallizer for about 10mm, and the aluminum liquid fills the cavity formed by the base and the inner wall of the crystallizer; after the cavity is filled to the set liquid level and the set time is reached, the base starts to move downwards at the set speed, at the moment, the aluminum alloy in the cavity forms a solidified shell with a certain thickness, along with the downward movement of the dummy bar head, the facets of the solidified shell of the flat ingot are contacted with cooling water, the facets are cooled rapidly, two sides of the facets are separated from the dummy bar head and lift, along with the continuous downward movement of the dummy bar head, the solidified shell formed after the facets is contacted with the cooling water, the ingot is subjected to rapid waisting phenomenon, gaps are formed between the facets and the inner wall of the crystallizer, if the gaps are larger than round corners formed by the surface tension of the aluminum liquid, the aluminum liquid leaks along the gaps, and if the aluminum leakage of the facets on two sides is inconsistent (cannot be completely consistent in actual production), the continuous lifting process of the facets is blocked, the apparent phenomenon is that the lifting heights of the facets on two sides (the distance between the facets and the dummy bar head) are inconsistent, and at the moment, the gravity center of gravity of the ingot is shifted; with the increase of the length of the ingot, the dead weight of the ingot increases, and when the dead weight reaches a certain degree, the gravity center gradually returns under the dead weight effect, the ingot shakes, and the ingot bends.
If aluminum leakage of the small surface is found in the production process, casting can only be continued, and finally cast ingot bending or casting stopping and restarting are finally caused, the tilting conditions of the two sides of the small surface are not observed and compared, measures are not taken, and the bending of the small surface of the cast ingot or casting stopping and restarting are often caused;
1. after bending, the cast ingot needs to be subjected to facet milling, so that equipment loss is increased, and the yield is reduced; restarting casting, namely, re-heating a stopper rod, re-installing a new distribution bag, re-heating and other preparation works, wherein the temperature of the melt is required to be adjusted again, so that a great amount of manpower and material resources are wasted;
2. if the bending of the small surface of the cast ingot is serious or the small surface milling equipment is not available to manufacturers, the cast ingot can only be scrapped, the cost is increased, and the yield is reduced.
The application provides an improved ingot casting bending tool and application thereof: as described above, if the aluminum leakage phenomenon occurs on the small surfaces during casting, the tilting heights of the two sides of the ingot are observed at the required time, if the tilting heights of the small surfaces on the two sides are inconsistent, when the length of the ingot reaches about 300mm, tilting of the two sides of the ingot is completed, the tool is used for being placed between the dummy ingot head and the tilted ingot gap, one tool is placed on each of the two sides, the follow-up ingot is prevented from being bent due to dead weight and change of the gravity center of the ingot, and the placed tool must bear about 15t of weight without deformation or position looseness.
If aluminum leakage of the facets is found during casting of the flat ingot, observing the tilting heights of the facets, and judging whether measures are to be taken or not by judging whether the tilting heights of the facets on two sides are consistent; if the tilting heights of the facets on two sides are inconsistent, the fixture is placed between the gap of the dummy ingot head and the gap of the ingot, one fixture is placed on each surface side, and the placed fixture must bear the weight of about 15t without deformation or position looseness; the detachable tool part of the application needs to be completely matched with the warped cast ingot and the base. In the general production process, the degree of warping of the same type of aluminum alloy is within a certain range, so that the required detachable tool part can be estimated and prepared in advance.
Example 1
409 alloy was prepared with ingot specifications of 450mm x 560 mm x 5000mm:
alloy composition: si:11-13wt%, fe:0.8wt%, cu:0.3wt%, mn:0.15wt% of Al and less than 0.05wt% of unavoidable impurities.
The alloy has silicon content close to that of eutectic composition and good fluidity.
Manufacturing a detachable tool part: the method comprises the steps of firstly, processing the upper surface and the lower surface into sections with the same radian as that of a dummy bar head, and then, making the upper surface into a sawtooth shape with the tooth height of 5 mm;
smelting: charging 409 alloy, heating to 750-780 ℃, and skimming slag; refining and standing after ingredients are regulated;
casting: adjusting the temperature of the melt to 690-700 ℃, and drying the preparation work before casting such as launders, filter boxes and the like;
in the casting process, the leakage of the small surface is found, the difference of the warping heights of the two sides of the small surface of the cast ingot is relatively large, the tool is timely placed at the gaps of the two sides of the bottom of the dummy ingot head and the bottom of the cast ingot, the lower section is completely attached to the dummy ingot head, the upper surface is completely used for supporting the cast ingot due to the sawteeth shape, the cast ingot is not swayed until the casting is finished, the cast ingot is observed after the casting is finished, and the cast ingot is not bent (shown in figure 3).
Example 2
409 alloy was prepared with ingot specifications of 450mm x 1330mm x 5000mm:
alloy composition: si:11-13wt%, fe:0.8wt%, cu:0.3wt%, mn:0.15wt% of Al and less than 0.05wt% of unavoidable impurities.
The alloy has silicon content close to that of eutectic composition and good fluidity.
Manufacturing a detachable tool part: the method comprises the steps of firstly, processing the upper surface and the lower surface into sections with the same radian as that of a dummy bar head, and then, making the upper surface into a sawtooth shape with the tooth height of 5 mm;
smelting: charging 409 alloy, heating to 750-780 ℃, and skimming slag; refining and standing after ingredients are regulated;
casting: adjusting the temperature of the melt to 690-700 ℃, and drying the preparation work before casting such as launders, filter boxes and the like;
in the casting process, the leakage of the small surface is found, the difference of the warping heights of the two sides of the small surface of the cast ingot is relatively large, the tool is timely placed at the gaps of the two sides of the bottom of the dummy ingot head and the bottom of the cast ingot, the lower section is completely attached to the dummy ingot head, the upper surface is in a saw-tooth shape and is used for completely supporting the cast ingot until the casting is finished, the cast ingot is not rocked, the cast ingot is observed after the casting is finished, and the cast ingot is not bent.
Example 3
Preparing 403 alloy, wherein the ingot casting specification is 450mm x 5000mm:
alloy composition: si:9-11wt%, fe:0.8wt%, cu:0.3wt%, mg:0.03wt% of Al and less than 0.05wt% of unavoidable impurities.
The alloy has high silicon content and good fluidity.
Manufacturing a detachable tool part: the method comprises the steps of firstly, processing the upper surface and the lower surface into sections with the same radian as that of a dummy bar head, and then, making the upper surface into a sawtooth shape with the tooth height of 5 mm;
smelting: heating 403 alloy to 750-780 ℃ for slag skimming; refining and standing after ingredients are regulated;
casting: adjusting the temperature of the melt to 690-700 ℃, and drying the preparation work before casting such as launders, filter boxes and the like;
in the casting process, the leakage of the small surface is found, the difference of the warping heights of the two sides of the small surface of the cast ingot is relatively large, the tool is timely placed at the gaps of the two sides of the bottom of the dummy ingot head and the bottom of the cast ingot, the lower section is completely attached to the dummy ingot head, the upper surface is in a saw-tooth shape and is used for completely supporting the cast ingot until the casting is finished, the cast ingot is not rocked, the cast ingot is observed after the casting is finished, and the cast ingot is not bent.
Comparative example 1
409 alloy was prepared with ingot specifications of 450mm x 560 mm x 5000mm.
The remaining steps were the same as in the examples, but when the casting was carried out to a length of 300mm and the aluminum leakage from the facets was found to result in inconsistent warpage, no removable tooling parts were placed and the resulting ingot was bent (as shown in fig. 4).
The above description of the embodiments is only for aiding in the understanding of the method of the present application and its core ideas. It should be noted that it will be apparent to those skilled in the art that various modifications and adaptations of the application can be made without departing from the principles of the application and these modifications and adaptations are intended to be within the scope of the application as defined in the following claims.
Claims (10)
1. A dummy bar head, comprising: a base and a detachable tooling component;
when the casting length of the cast aluminum alloy ingot is 300+/-100 mm, the two sides of the facet warp to enter a stable stage; when the two-side warps generate the height difference, the detachable tool part is placed at a gap between the base and the two-side warps.
2. The dummy bar head according to claim 1, characterized in that the detachable tooling part is placed at the gap between the base and the two side warps when the two side warps differ in height by > 10 mm.
3. The dummy bar head according to claim 1, wherein the detachable tooling member is a rectangular parallelepiped or a square;
preferably, the wall thickness of the detachable tool part is more than 10mm;
preferably, the detachable tool part is a cube with the length, width and height of 100+/-10 mm.
4. A dummy bar head according to claim 3, wherein the face of the detachable tooling member which meets the base is the same as the base arc.
5. The dummy bar head of claim 4, wherein the face of the detachable tooling member that interfaces with the aluminum alloy ingot is provided with a protrusion.
6. The dummy bar head of claim 5, wherein the protrusions are saw tooth protrusions.
7. The dummy bar head of claim 6, wherein the pressure that the detachable tooling member can withstand is greater than 15 tons.
8. The dummy bar head of claim 7, wherein the material of the detachable tooling member is selected from the group consisting of steel returns.
9. A method for preventing aluminum leakage from bending on the small surface of an aluminum alloy ingot, which is characterized in that the dummy ingot head according to any one of claims 1 to 8 is used for casting the aluminum alloy ingot.
10. The method according to claim 9, comprising:
in the step of casting the aluminum alloy ingot above the base, when the casting length of the cast aluminum alloy ingot is 300+/-100 mm, the two sides of the facet warp to enter a stable stage;
if the warpage height difference is greater than 10mm, placing the detachable tool part at a gap between the base and the two side warpage, so that the lower surface of the detachable tool part is completely attached to the base, and the upper surface of the detachable tool part is completely supported at the two side warpage parts of the ingot until casting is finished.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202310958835.7A CN116786774A (en) | 2023-07-31 | 2023-07-31 | Dummy ingot head and method for preventing aluminum leakage bending of aluminum alloy ingot casting facet |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202310958835.7A CN116786774A (en) | 2023-07-31 | 2023-07-31 | Dummy ingot head and method for preventing aluminum leakage bending of aluminum alloy ingot casting facet |
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| Publication Number | Publication Date |
|---|---|
| CN116786774A true CN116786774A (en) | 2023-09-22 |
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| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN202310958835.7A Pending CN116786774A (en) | 2023-07-31 | 2023-07-31 | Dummy ingot head and method for preventing aluminum leakage bending of aluminum alloy ingot casting facet |
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| Country | Link |
|---|---|
| CN (1) | CN116786774A (en) |
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2023
- 2023-07-31 CN CN202310958835.7A patent/CN116786774A/en active Pending
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