EP1607156B1 - Casting method and installation for casting aluminium or aluminium alloys - Google Patents

Casting method and installation for casting aluminium or aluminium alloys Download PDF

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Publication number
EP1607156B1
EP1607156B1 EP04405366A EP04405366A EP1607156B1 EP 1607156 B1 EP1607156 B1 EP 1607156B1 EP 04405366 A EP04405366 A EP 04405366A EP 04405366 A EP04405366 A EP 04405366A EP 1607156 B1 EP1607156 B1 EP 1607156B1
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EP
European Patent Office
Prior art keywords
casting
ladles
station
molten aluminium
aluminium
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Not-in-force
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EP04405366A
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German (de)
French (fr)
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EP1607156A1 (en
Inventor
Dirk Kotze
Dawid Dewet-Smith
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Stopinc AG
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Stopinc AG
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Priority to DE502004008913T priority Critical patent/DE502004008913D1/en
Application filed by Stopinc AG filed Critical Stopinc AG
Priority to AT04405366T priority patent/ATE421398T1/en
Priority to EP04405366A priority patent/EP1607156B1/en
Priority to US11/629,712 priority patent/US20080164000A1/en
Priority to JP2007515884A priority patent/JP2008502483A/en
Priority to CA002570361A priority patent/CA2570361A1/en
Priority to RU2007101384/02A priority patent/RU2007101384A/en
Priority to CNA2005800198473A priority patent/CN1976773A/en
Priority to PCT/EP2005/006486 priority patent/WO2005123304A2/en
Priority to AU2005254220A priority patent/AU2005254220A1/en
Priority to MXPA06014600A priority patent/MXPA06014600A/en
Publication of EP1607156A1 publication Critical patent/EP1607156A1/en
Priority to ZA200609947A priority patent/ZA200609947B/en
Application granted granted Critical
Publication of EP1607156B1 publication Critical patent/EP1607156B1/en
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D47/00—Casting plants

Definitions

  • the invention relates to a casting method for aluminum or aluminum alloys according to the preamble of claim 1 and a casting installation for carrying out the method.
  • the individual treatment stations must be perfectly coordinated. If one of the stages of this in-line system does not work, the entire casting plant must be shut down.
  • the long channel through which the melt passes means a loss of temperature, so that the material in the heat-holding furnace must be overheated, so that a sufficient temperature can be reached at the casting station at start-up. Extensive casting times mean that the melting and holding furnace must be available for the entire casting time before the next melting rate is used.
  • the energy consumption of the stove is correspondingly large.
  • flue furnaces reverberatory furnaces
  • hydrocarbon hydrocarbon are used as fuel, which causes the disadvantage of rapid absorption of hydrogen from the burner flame.
  • greenhouse gases and other pollutants polluting the atmosphere are produced.
  • the long, open channel for the flow through the melt also means that the metal absorbs the hydrogen from the atmosphere and causes the formation of slag.
  • the present invention has for its object to provide a more economical and flexible casting process for aluminum or aluminum alloys and a casting plant for performing the To provide a method that allow optimal timing for the treatment and casting of the molten aluminum and with which an improved quality of the semi-products to be produced can be achieved.
  • pans for the treatment and feeding of Alauschmelze in controllable sequences to preferably several Giessstationen this process phase is decoupled from the actual casting process in time.
  • the individual treatments are no longer fix fixed and limited in time, but they can be adjusted as needed until the desired quality of the melt to be poured in the respective pan is achieved.
  • the inventive method is much more efficient than the in-line method, since the need for large heat holding furnace is eliminated. If anything, the furnaces are used for melting and heating, but not for keeping heat for long periods of time. These can be designed as an energetically efficient and ecologically advantageous induction furnace.
  • Fig. 1 shows a prior art casting plant 1 for aluminum or aluminum alloys.
  • liquid or solid aluminum is introduced into a first stage or station 2, which comprises a melting furnace 3 and a heat-holding furnace 4 connected to it.
  • the aluminum may be delivered from a filling space by means of a transporting pan 5 or as a scrapload.
  • the furnaces 3, 4 are generally large flame furnaces with hydrocarbon as fuel.
  • the melt produced in the melting furnace 3 is heated in the heat holding furnace 4 to the necessary temperature and partially homogenized by stirring.
  • the aluminum melt After the aluminum melt has reached the required temperature, it is passed from the heat holding furnace 4 via a long channel 6 (channel) to a casting station 7, wherein it passes through various treatment stations 11, 12, which together with a casting station 7 upstream filter 13 a second Form 10 of the casting plant 1 generally known as gutter treatment.
  • a second Form 10 of the casting plant 1 generally known as gutter treatment.
  • the treatment station 11 the Alauschmelze various alloying additions are added.
  • a gas cleaning takes place.
  • the casting station 7, in which the molten aluminum is poured into semi-products, can be operated continuously or semi-continuously in a manner known per se and therefore not described in more detail.
  • the treatment times in the gutter stage 10 are bound to the casting process to be performed in the casting station 7 and thus predetermined and limited.
  • the individual treatment stations 11, 12, 13 must be perfectly matched in their function in terms of time. If one of the stages of this in-line system does not work, the entire casting plant 1 must be shut down.
  • the long channel or channel 6, through which the melt flows, means a loss of temperature, so that the material in the heat holding furnace 4 must be overheated (eg to 730 ° C), so that at the casting station 7 a sufficient temperature when starting (eg 700 ° C) can be achieved.
  • Extensive casting times mean that the melting and holding furnace 4 must be available for the entire casting time before next melting rate is used.
  • the energy consumption of the oven 3, 4 is correspondingly large.
  • Fig. 2 an inventive casting plant 1 for aluminum or aluminum alloys is shown schematically.
  • the first stage of the casting process according to the invention takes place in a filling station 21, in which hot aluminum melt is filled into a number of pans 25.
  • the pans for example, have a capacity of 15 t. It can either liquid, hot (temperature about 900 ° C) aluminum from a filling space by means of transport ladles are filled directly into the pans 25, or it is at least one, preferably more furnace 22, 23, 24 of the filling station 21 assigned and for the delivery responsible for the Alauschmelze, in addition to liquid aluminum also aluminum scrap or intended for remelting blocks can serve as starting material.
  • the melt can be filled into one of the pans 25 at half-hourly intervals.
  • aluminum melt of different quality are filled into the pans 25, wherein the filling of the pans 25 with Alauschmelze possibly even with mixed material from different furnace 22, 23, 24 may be computer controlled.
  • furnace 22, 23, 24 can preferably be used electric induction furnace, which are much more efficient energy than flame furnace.
  • This may be, for example, an induction furnace with a capacity of 20 t, from each of which the 15 t aluminum melt is filled into one of the pans 25 and the remaining 5 t are helpful in melting a further charge.
  • the casting installation 1 has a cleaning and preparation station 30 from which cleaned and preheated pans 25a are transported for filling to the filling station 21 (pans 25 located on a transport route are in FIG Fig. 2 generally indicated by the letter T).
  • a cleaning and preparation station 30 from which cleaned and preheated pans 25a are transported for filling to the filling station 21 (pans 25 located on a transport route are in FIG Fig. 2 generally indicated by the letter T).
  • the slag is skimmed off from the surface of the molten bath by bringing the pan 25 into an inclined position.
  • the pans 25 filled in the filling station 21 are transported to a treatment station 32, in which the second stage of the casting process runs.
  • alloying additives are first introduced into the aluminum melt (compare the pans designated 25b in FIG Fig. 2 ). (However, at least some of the alloying additives can also be introduced into the cleaned pans 25a before the melt is introduced.)
  • the aluminum melt is homogenized and cleaned (compare pans 25c).
  • the pans are placed below an impeller immersed in the respective pan 25c for blowing an inert gas, for example argon or nitrogen, wherein a combined hydrogen removal, homogenization and / or thermal regulation of the aluminum melt can take place.
  • the injection of argon eliminates the absorption of hydrogen from the moisture present in the atmosphere and reduces slag formation.
  • small amounts of chlorine may be added to the purge gas.
  • the pans 25 can be stored in designated storage stations (in Fig. 2 are generally such storage stations with the letter S) are held until a casting station 33 and 34 is available.
  • the casting plant 20 preferably has over several such casting stations (in Fig. 2 two shown), to which the pans 25 can be transported from the treatment or storage station, and in which the melt is poured into semi-finished products.
  • the pans 25 can be covered with a lid with advantage.
  • the temperature in the pan 25 can be reduced by blowing argon through a porous plug in the pan bottom or maintained or increased by means of a small burner built into the pan lid.
  • the emptying of the pans 25d at the respective casting station 33, 34 takes place through the bottom of the pan with controllable opening of a sliding closure, wherein the outflowing aluminum melt is conducted into a collecting channel, preferably under sheath by an inert gas. Also during this phase argon can be blown through the porous plug in the pan bottom, whereby the melt is stirred and purified.
  • inert atmosphere can be created in its upper region, which reduces the oxidation and absorption of hydrogen.
  • the casting stations 33, 34 are each equipped in a manner known per se with a filter system and are operated continuously or semi-continuously.
  • pans 25d After emptying the pans 25d they are transported to the already mentioned cleaning and preparation station 30 and in this cleaned (see pan 25e) and prepared for reuse, in particular preheated (see pan 25a).
  • the emptied pans can also be stored until reuse in designated storage stations S.
  • pans 25 For the transport of the pans 25 from one station to the next or to the storage stations S multiple ways are provided, wherein the pans 25 can be transported on rails or by means of overhead cranes.
  • the casting plant according to the invention is equipped with a control system with which the batches to be filled from individual ovens 22, 23, 24 into the individual pans 25, the alloying additions, heating, cooling, gas supply and treatment times are controlled so that the aluminum melt in the desired quality, with desired Temperature and fully homogenized to the Giessstationen 33, 34 passes.
  • pans 25 for the treatment and feeding of Alauschmelze in controllable sequences to preferably several Giessstationen 33, 34, this process phase is decoupled from the actual casting process in time.
  • the individual treatments are no longer fix fixed and limited in time, but they can be adjusted as needed, until the desired quality of the molten aluminum to be poured in the respective pan is achieved. If, for example, a low hydrogen content is required, the gas purification time ( degassing ) can be extended. This possibility existed in the traditional in-line method Fig. 1 Not.
  • the production capacity of the casting plant depends on the actual casting process at the casting stations alone, which can be continued until the feed the treated Alauschmelze is interrupted to the Giessstationen in a desired manner.
  • the inventive method is much more efficient than the inline method, since the need for large heat holding furnace is eliminated. If anything, the furnaces are needed for melting and heating, but not for keeping heat for long periods of time. These can be designed as an energetically efficient and ecologically advantageous induction furnace. By preheating the pans, the temperature of the melt which can be reached in the ovens can be a lower value.

Abstract

Al and Al alloy casting process in which the Al melt is added to at least one casting station (33, 34) where the melt is cast to a semifinished product. In adding the Al melt to the casting station a number of ladles (25) are used, into which the melt is filled, transported and treated in a further step (32) and finally fed to casting stations 33 or 34 with removal of the ladles. An independent claim is included for a casting unit as described above.

Description

Die Erfindung betrifft ein Giessverfahren für Aluminium bzw. Aluminiumlegierungen gemäss dem Oberbegriff des Anspruches 1 sowie eine Giessanlage zum Durchführen des Verfahrens.The invention relates to a casting method for aluminum or aluminum alloys according to the preamble of claim 1 and a casting installation for carrying out the method.

Es sind Giessverfahren sowie Giessanlagen für Aluminium bzw. Aluminiumlegierungen bekannt (Prospekt, BAYSIDE Aluminium, Aluminium Manufacturing Process, 2003), bei denen festes oder flüssiges Aluminium in einem Schmelzofen geschmolzen und anschliessend in einem Wärmehalteofen gehalten wird, aus welchem die Schmelze über eine lange Rinne zu einer Giesstation fliesst und dabei unterschiedlicher Behandlung ausgesetzt wird. So werden der die Rinne durchfliessenden Schmelze Legierungszusätze zugegeben und ein inertes Reinigungsgas (Argon) eingeblasen, bevor die Schmelze über einen Filter zu der Giesstation gelangt, in der sie zu Halbprodukten vergossen wird (vgl. Fig. 1, in der eine herkömmliche Giessanlage für Aluminium schematisch dargestellt ist). Eine Homogenisierung der Schmelze ist nur begrenzt möglich. Die Behandlungszeiten sind an den Giessprozess gebunden und somit vorbestimmt und zeitlich begrenzt.There are known casting and casting systems for aluminum or aluminum alloys (Prospectus, BAYSIDE Aluminum, Aluminum Manufacturing Process, 2003), in which solid or liquid aluminum is melted in a melting furnace and then held in a heat holding furnace, from which the melt through a long groove flows to a casting station and is subjected to different treatment. Thus, alloying additives are added to the melt flowing through the channel and an inert cleaning gas (argon) is injected before the melt passes through a filter to the casting station, where it is cast into semi-finished products (cf. Fig. 1 in which a conventional casting plant for aluminum is shown schematically). A Homogenization of the melt is limited. The treatment times are bound to the casting process and thus predetermined and limited in time.

Die einzelnen Behandlungsstationen müssen perfekt aufeinander abgestimmt sein. Funktioniert eine der Stufen dieser In-line-Anlage nicht, so muss die ganze Giessanlage ausser Betrieb gesetzt werden. Die lange Rinne, die die Schmelze durchfliesst, bedeutet einen Temperaturverlust, so dass das Material in dem Wärmehalteofen überhitzt werden muss, damit an der Giessstation eine genügende Temperatur beim Anfahren erreicht werden kann. Extensive Giesszeiten bedeuten, dass der Schmelz- und Wärmehalteofen für die ganze Giesszeit zur Verfügung stehen muss, bevor nächste Schmelzrate zum Einsatz kommt. Der Energieverbrauch der Ofen ist entsprechend gross. Es werden in der Regel Flammenofen (reverberatory furnaces) mit Kohlenwasserstoff als Brennstoff verwendet, wodurch der Nachteil einer rapiden Absorption von Wasserstoff aus der Brennerflamme entsteht. Zudem entstehen Treibhausgase und andere die Atmosphäre belastende Verunreinigungen. Die lange, offene Rinne für den Durchfluss der Schmelze bedeutet aber auch, dass das Metall den Wasserstoff von der Atmosphäre aufnimmt und die Bildung von Schlacke verursacht.The individual treatment stations must be perfectly coordinated. If one of the stages of this in-line system does not work, the entire casting plant must be shut down. The long channel through which the melt passes means a loss of temperature, so that the material in the heat-holding furnace must be overheated, so that a sufficient temperature can be reached at the casting station at start-up. Extensive casting times mean that the melting and holding furnace must be available for the entire casting time before the next melting rate is used. The energy consumption of the stove is correspondingly large. As a rule, flue furnaces ( reverberatory furnaces ) with hydrocarbon are used as fuel, which causes the disadvantage of rapid absorption of hydrogen from the burner flame. In addition, greenhouse gases and other pollutants polluting the atmosphere are produced. However, the long, open channel for the flow through the melt also means that the metal absorbs the hydrogen from the atmosphere and causes the formation of slag.

Es ist gemäss der Druckschrift DE-A-37 36 117 eine Anlage jedoch für die Herstellung von Stahl bekannt, bei der in einem Ofen der Stahl geschmolzen und in Pfannen abgefüllt und mit diesen eine kontinuierliches Vergiessen erfolgt. Die verschiedenen Behandlungsstationen, welche durch Elektroofen bzw. durch Pfannen gebildet sind, sollen derart räumlich angeordnet sein, dass sie geradlinig zueinander verlaufen.It is according to the document DE-A-37 36 117 However, a plant known for the production of steel, in which the steel is melted in an oven and filled into pans and with these a continuous casting takes place. The various treatment stations, which are formed by electric furnace or by pans, should be arranged spatially so that they are rectilinear to each other.

Der vorliegenden Erfindung liegt die Aufgabe zugrunde, ein wirtschaftlicheres und flexibleres Giessverfahren für Aluminium bzw. Aluminiumlegierungen vorzuschlagen sowie eine Giessanlage zum Durchführen des Verfahrens zu schaffen, die einen optimalen Zeitablauf für das Behandeln und das Vergiessen der Aluminiumschmelze ermöglichen und mit denen eine verbesserte Qualität der zu erzeugenden Halbprodukte erreicht werden kann.The present invention has for its object to provide a more economical and flexible casting process for aluminum or aluminum alloys and a casting plant for performing the To provide a method that allow optimal timing for the treatment and casting of the molten aluminum and with which an improved quality of the semi-products to be produced can be achieved.

Diese Aufgabe wird erfindungsgemäss durch ein Giessverfahren mit den Merkmalen des Anspruches 1 sowie durch eine Giessanlage mit den Merkmalen des Anspruches 13 gelöst.This object is achieved according to the invention by a casting method having the features of claim 1 and by a casting installation having the features of claim 13.

Bevorzugte Weitergestaltungen des erfindungsgemässen Giessverfahrens sowie der erfindungsgemässen Giessanlage bilden den Gegenstand der abhängigen Ansprüche.Preferred refinements of the casting method according to the invention and the casting installation according to the invention form the subject of the dependent claims.

Durch die erfindungsgemässe Verwendung von Pfannen für das Behandeln und Zuführen von Aluschmelze in steuerbaren Sequenzen zu vorzugsweise mehreren Giessstationen wird diese Verfahrensphase von dem eigentlichen Giessvorgang zeitlich abgekoppelt. Die einzelnen Behandlungen sind nicht mehr fix festgelegt und zeitlich begrenzt, sondern sie können nach Bedarf angepasst werden, bis die gewünschte Qualität der zu vergiessenden Schmelze in der jeweiligen Pfanne erreicht wird.By the inventive use of pans for the treatment and feeding of Alauschmelze in controllable sequences to preferably several Giessstationen this process phase is decoupled from the actual casting process in time. The individual treatments are no longer fix fixed and limited in time, but they can be adjusted as needed until the desired quality of the melt to be poured in the respective pan is achieved.

Das erfindungsgemässe Verfahren ist wesentlich effizienter als das In-line-Verfahren, da die Notwendigkeit von grossen Wärmehalteofen entfällt. Wenn überhaupt, werden die Ofen zum Schmelzen und Aufheizer gebraucht, jedoch nicht zum Wärmehalten über längere Zeitabschnitte. Diese können als energetisch effiziente und ökologisch vorteilhafte Induktionsofen ausgebildet sein.The inventive method is much more efficient than the in-line method, since the need for large heat holding furnace is eliminated. If anything, the furnaces are used for melting and heating, but not for keeping heat for long periods of time. These can be designed as an energetically efficient and ecologically advantageous induction furnace.

Die Erfindung wird nachfolgend anhand der Zeichnung näher erläutert. Es zeigen:

Fig. 1
schematisch ein Ausführungsbeispiel einer dem Stand der Technik entsprechenden Giessanlage für Aluminium; und
Fig.2
schematisch ein Ausführungsbeispiel einer erfindungsgemässen Giessanlage für Aluminium.
The invention will be explained in more detail with reference to the drawing. Show it:
Fig. 1
schematically an embodiment of a prior art casting plant for aluminum; and
Fig.2
schematically an embodiment of an inventive casting plant for aluminum.

Fig. 1 zeigt eine dem Stand der Technik entsprechende Giessanlage 1 für Aluminium bzw. Aluminiumlegierungen. Als Ausgangsmaterial wird flüs- siges oder festes Aluminium in eine erste Stufe bzw. Station 2 eingebracht, die einen Schmelzofen 3 sowie einen an diesen angeschlossenen Wärmehalteofen 4 umfasst. Beispielsweise kann das Aluminium aus einem Füllraum mittels einer Transportpfanne 5 oder als eine Schrottladung geliefert werden. Bei den Ofen 3, 4 handelt es sich in der Regel um grosse Flammenofen mit Kohlenwasserstoff als Brennstoff. Die im Schmelzofen 3 erzeugte Schmelze wird im Wärmehalteofen 4 auf die notwendige Temperatur erhitzt und teilweise durch Rühren homogenisiert. Fig. 1 shows a prior art casting plant 1 for aluminum or aluminum alloys. As starting material, liquid or solid aluminum is introduced into a first stage or station 2, which comprises a melting furnace 3 and a heat-holding furnace 4 connected to it. For example, the aluminum may be delivered from a filling space by means of a transporting pan 5 or as a scrapload. The furnaces 3, 4 are generally large flame furnaces with hydrocarbon as fuel. The melt produced in the melting furnace 3 is heated in the heat holding furnace 4 to the necessary temperature and partially homogenized by stirring.

Nachdem die Aluminiumschmelze die erforderliche Temperatur erreicht hat, wird sie aus dem Wärmehalteofen 4 über eine lange Rinne 6 (Kanal) zu einer Giessstation 7 geleitet, wobei sie verschiedene Behandlungsstationen 11, 12 durchfliesst, die zusammen mit einem der Giessstation 7 vorgeschalteten Filter 13 eine zweite Stufe 10 der Giessanlage 1 allgemein bekannt als Rinnenbehandlung bilden. In der Behandlungsstation 11 werden der Aluschmelze diverse Legierungszusätze zugefügt. In der Behandlungsstation 12 findet eine Gasreinigung statt.After the aluminum melt has reached the required temperature, it is passed from the heat holding furnace 4 via a long channel 6 (channel) to a casting station 7, wherein it passes through various treatment stations 11, 12, which together with a casting station 7 upstream filter 13 a second Form 10 of the casting plant 1 generally known as gutter treatment. In the treatment station 11 the Alauschmelze various alloying additions are added. In the treatment station 12, a gas cleaning takes place.

Die Giessstation 7, in der die Aluminiumschmelze zu Halbprodukten vergossen wird, kann in einer an sich bekannten und daher nicht näher beschriebenen Weise kontinuierlich oder halbkontinuierlich betrieben werden.The casting station 7, in which the molten aluminum is poured into semi-products, can be operated continuously or semi-continuously in a manner known per se and therefore not described in more detail.

Die Behandlungszeiten in der Rinnen-Stufe 10 sind an den in der Giessstation 7 durchzuführenden Giessprozess gebunden und somit vorbestimmt und begrenzt. Die einzelnen Behandlungsstationen 11, 12, 13 müssen in ihrer Funktion zeitlich perfekt aufeinander abgestimmt sein. Funktioniert eine der Stufen dieser In-line-Anlage nicht, so muss die ganze Giessanlage 1 ausser Betrieb gesetzt werden. Der lange Kanal bzw. Rinne 6, durch die die Schmelze fliesst, bedeutet einen Temperaturverlust, so dass das Material in dem Wärmehalteofen 4 überhitzt werden muss (z.B. auf 730°C), damit an der Giessstation 7 eine genügende Temperatur beim Anfahren (z.B. 700°C) erreicht werden kann. Extensive Giesszeiten bedeuten, dass der Schmelz- und Wärmehalteofen 4 für die ganze Giesszeit zur Verfügung stehen muss, bevor nächste Schmelzrate zum Einsatz kommt. Der Energieverbrauch der Ofen 3, 4 ist entsprechend gross.The treatment times in the gutter stage 10 are bound to the casting process to be performed in the casting station 7 and thus predetermined and limited. The individual treatment stations 11, 12, 13 must be perfectly matched in their function in terms of time. If one of the stages of this in-line system does not work, the entire casting plant 1 must be shut down. The long channel or channel 6, through which the melt flows, means a loss of temperature, so that the material in the heat holding furnace 4 must be overheated (eg to 730 ° C), so that at the casting station 7 a sufficient temperature when starting (eg 700 ° C) can be achieved. Extensive casting times mean that the melting and holding furnace 4 must be available for the entire casting time before next melting rate is used. The energy consumption of the oven 3, 4 is correspondingly large.

Bei den Flammenofen mit Kohlenwasserstoff als Brennstoff entsteht der Nachteil einer rapiden Absorption von Wasserstoff aus der Brennerflamme. Zudem entstehen Treibhausgase und andere die Atmosphäre belastende Verunreinigungen. Die lange, offene Rinne 6 (Kanal) für den Durchfluss der Aluschmelze bedeutet aber auch, dass das Metall den Wasserstoff von der Atmosphäre aufnimmt und die Bildung von Schlacke verursacht.In the case of the flame furnace with hydrocarbon as fuel, the disadvantage of rapid absorption of hydrogen from the burner flame arises. In addition, greenhouse gases and other pollutants polluting the atmosphere are produced. However, the long, open channel 6 (channel) for the flow of the molten metal also means that the metal absorbs the hydrogen from the atmosphere and causes the formation of slag.

In Fig. 2 ist eine erfindungsgemässe Giessanlage 1 für Aluminium bzw. Aluminiumlegierungen schematisch dargestellt. Die erste Stufe des erfindungsgemässen Giessverfahrens erfolgt in einer Füllstation 21, in welcher heisse Aluschmelze in eine Anzahl von Pfannen 25 gefüllt wird. Die Pfannen können beispielsweise ein Fassungsvermögen von 15 t aufweisen. Es kann entweder flüssiges, heisses (Temperatur ca. 900°C) Aluminium aus einem Füllraum mittels Transportpfannen direkt in die Pfannen 25 eingefüllt werden, oder es ist mindestens ein, vorzugsweise mehrere Ofen 22, 23, 24 der Füllstation 21 zugeordnet und für die Lieferung der Aluschmelze zuständig, wobei neben flüssigem Aluminium auch Aluminiumschrott oder zum Umschmelzen vorgesehene Blöcke als Ausgangsmaterial dienen können. Die Schmelze kann z.B. in halbstündigen Intervallen jeweils in eine der Pfannen 25 eingefüllt werden. Mit Vorteil kann aus den einzelnen Öfen Aluschmelze unterschiedlicher Qualität (mit unterschiedlichem Aluminium-Reinheitsgrad) in die Pfannen 25 eingefüllt werden, wobei das Füllen der Pfannen 25 mit Aluschmelze allenfalls auch mit gemischtem Material aus verschiedenen Ofen 22, 23, 24 computergesteuert verlaufen kann.In Fig. 2 an inventive casting plant 1 for aluminum or aluminum alloys is shown schematically. The first stage of the casting process according to the invention takes place in a filling station 21, in which hot aluminum melt is filled into a number of pans 25. The pans, for example, have a capacity of 15 t. It can either liquid, hot (temperature about 900 ° C) aluminum from a filling space by means of transport ladles are filled directly into the pans 25, or it is at least one, preferably more furnace 22, 23, 24 of the filling station 21 assigned and for the delivery responsible for the Alauschmelze, in addition to liquid aluminum also aluminum scrap or intended for remelting blocks can serve as starting material. For example, the melt can be filled into one of the pans 25 at half-hourly intervals. Advantageously, from the individual furnaces aluminum melt of different quality (with different degree of aluminum purity) are filled into the pans 25, wherein the filling of the pans 25 with Alauschmelze possibly even with mixed material from different furnace 22, 23, 24 may be computer controlled.

Als Ofen 22, 23, 24 können vorzugsweise elektrische Induktionsofen eingesetzt werden, die energetisch wesentlich effizienter sind als Flammenofen. Es kann sich dabei beispielsweise um Induktionsofen mit einem Fassungsvermögen von 20 t handeln, aus denen jeweils die 15 t Aluminiumschmelze in eine der Pfannen 25 gefüllt und die restlichen 5t beim Schmelzen einer weiteren Ladung behilflich sind.As furnace 22, 23, 24 can preferably be used electric induction furnace, which are much more efficient energy than flame furnace. This may be, for example, an induction furnace with a capacity of 20 t, from each of which the 15 t aluminum melt is filled into one of the pans 25 and the remaining 5 t are helpful in melting a further charge.

Die erfindungsgemässe Giessanlage 1 verfügt über eine Reinigungs- und Vorbereitungsstation 30, aus welcher gereinigte und vorerhitzte Pfannen 25a zum Einfüllen zu der Füllstation 21 transportiert werden (sich auf einer Transportstrecke befindenden Pfannen 25 sind in Fig. 2 generell mit dem Buchstaben T bezeichnet). Durch die Vorheizung der Pfannen 25a auf beispielsweise 900°C kann die aus den mit einer Temperatur von ca. 800°C betriebenen Ofen 22, 23, 24 eingefüllte Aluschmelze länger in den Pfannen 25 verbleiben, bis sie auf die typische Giesstemperatur von 700°C absinkt, als es ohne Vorheizung der Fall wäre.The casting installation 1 according to the invention has a cleaning and preparation station 30 from which cleaned and preheated pans 25a are transported for filling to the filling station 21 (pans 25 located on a transport route are in FIG Fig. 2 generally indicated by the letter T). By preheating the pans 25a to 900 ° C, for example, from the with a temperature of approx. 800 ° C operated oven 22, 23, 24 filled Alauschmelze longer in the pans 25 remain until it drops to the typical pouring temperature of 700 ° C, as it would be without preheating.

Nach dem Einfüllen der jeweilige Pfanne 25 wird von der Schmelzbadoberfläche die Schlacke abgeschöpft, indem die Pfanne 25 in eine Schrägstellung gebracht wird.After filling the respective pan 25, the slag is skimmed off from the surface of the molten bath by bringing the pan 25 into an inclined position.

Die in der Füllstation 21 gefüllten Pfannen 25 werden zu einer Behandlungsstation 32 transportiert, in welcher die zweite Stufe des Giessverfahrens verläuft. Dabei werden zuerst Legierungszusätze in die Aluschmelze eingebracht (vgl. die mit 25b bezeichnete Pfannen in Fig. 2). (Allerdings kann auch zumindest ein Teil der Legierungszusätze bereits in die gereinigten Pfannen 25a vor dem Einfüllen der Schmelze eingebracht werden.) Danach wird die Aluschmelze homogenisiert und gereinigt (vgl. Pfannen 25c). Zu diesem Zweck werden die Pfannen unterhalb eines in die jeweilige Pfanne 25c eintauchbaren Gebläserades zum Einblasen von einem Inertgas, z.B. Argon oder Stickstoff, platziert , wobei eine kombinierte Wasserstoffentfernung, Homogenisierung und/oder Wärmeregulierung der Aluschmelze erfolgen kann. Mit dem Einblasen von Argon wird die Absorption von Wasserstoff von der in der Atmosphäre vorhandenen Feuchtigkeit eliminiert und die Schlackenbildung reduziert. Zur Beseitigung von alkalischen Spurverunreinigungen können zusätzlich kleine Mengen von Chlorin dem Reinigungsgas beigemischt werden.The pans 25 filled in the filling station 21 are transported to a treatment station 32, in which the second stage of the casting process runs. In this case, alloying additives are first introduced into the aluminum melt (compare the pans designated 25b in FIG Fig. 2 ). (However, at least some of the alloying additives can also be introduced into the cleaned pans 25a before the melt is introduced.) Thereafter, the aluminum melt is homogenized and cleaned (compare pans 25c). For this purpose, the pans are placed below an impeller immersed in the respective pan 25c for blowing an inert gas, for example argon or nitrogen, wherein a combined hydrogen removal, homogenization and / or thermal regulation of the aluminum melt can take place. The injection of argon eliminates the absorption of hydrogen from the moisture present in the atmosphere and reduces slag formation. To remove alkaline trace impurities, small amounts of chlorine may be added to the purge gas.

Nach der Behandlung der Aluminiumschmelze können die Pfannen 25 in dafür vorgesehenen Lagerstationen (in Fig. 2 sind generell solche Lagerstationen mit dem Buchstaben S bezeichnet) gehalten werden, bis eine Giessstation 33 bzw. 34 verfügbar ist. Die Giessanlage 20 verfügt vorzugsweise über mehrere solche Giessstationen (in Fig. 2 zwei dargestellt), zu welchen die Pfannen 25 von der Behandlungs- oder Lagerstation transportiert werden können, und in welchen die Schmelze zu Halbprodukten vergossen wird.After treatment of the aluminum melt, the pans 25 can be stored in designated storage stations (in Fig. 2 are generally such storage stations with the letter S) are held until a casting station 33 and 34 is available. The casting plant 20 preferably has over several such casting stations (in Fig. 2 two shown), to which the pans 25 can be transported from the treatment or storage station, and in which the melt is poured into semi-finished products.

Zum Aufrechterhalten der Aluschmelze-Temperatur können mit Vorteil die Pfannen 25 mit einem Deckel abgedeckt werden.To maintain the Alauschmelze temperature, the pans 25 can be covered with a lid with advantage.

Während des Verweilens in der Lagerstation S kann die Temperatur in der Pfanne 25 durch Einblasen von Argon durch einen porösen Stöpsel im Pfannenboden hindurch herabgesetzt oder mittels eines in den Pfannendeckel eingebauten, kleinen Brenners aufrechterhalten oder erhöht werden.During the stay in the storage station S, the temperature in the pan 25 can be reduced by blowing argon through a porous plug in the pan bottom or maintained or increased by means of a small burner built into the pan lid.

Die Entleerung der Pfannen 25d an der jeweiligen Giessstation 33, 34 erfolgt durch den Pfannenboden unter steuerbarer Öffnung eines Schiebeverschlusses, wobei die ausfliessende Aluschmelze in einen Sammelkanal vorzugsweise unter Ummantelung durch ein Inertgas geleitet wird. Auch während dieser Phase kann durch den porösen Stöpsel im Pfannenboden Argon eingeblasen werden, wodurch die Schmelze gerührt und gereinigt wird. Durch Abdecken der Pfanne 25d kann in ihrem oberen Bereich inerte Atmosphäre geschaffen werden, die die Oxidation und Absorption von Wasserstoff herabsetzt.The emptying of the pans 25d at the respective casting station 33, 34 takes place through the bottom of the pan with controllable opening of a sliding closure, wherein the outflowing aluminum melt is conducted into a collecting channel, preferably under sheath by an inert gas. Also during this phase argon can be blown through the porous plug in the pan bottom, whereby the melt is stirred and purified. By covering the pan 25d, inert atmosphere can be created in its upper region, which reduces the oxidation and absorption of hydrogen.

Die Giessstationen 33, 34 sind jeweils in einer an sich bekannten Weise mit einem Filtersystem ausgerüstet und werden kontinuierlich oder halbkontinuierlich betrieben.The casting stations 33, 34 are each equipped in a manner known per se with a filter system and are operated continuously or semi-continuously.

Nach dem Entleeren der Pfannen 25d werden diese zu der bereits erwähnten Reinigungs- und Vorbereitungsstation 30 transportiert und in dieser gereinigt (vgl. Pfanne 25e) und für die Wiederverwendung vorbereitet, insbesondere vorerhitzt (vgl. Pfanne 25a). Die entleerten Pfannen können auch bis zum Wiedergebrauch in dafür vorgesehenen Lagerstationen S aufbewahrt werden.After emptying the pans 25d they are transported to the already mentioned cleaning and preparation station 30 and in this cleaned (see pan 25e) and prepared for reuse, in particular preheated (see pan 25a). The emptied pans can also be stored until reuse in designated storage stations S.

Für den Transport der Pfannen 25 von einer Station zu der nächsten oder zu den Lagerstationen S sind mehrfache Wege vorgesehen, wobei die Pfannen 25 auf Schienen oder mittels obliegender Kräne transportiert werden können.For the transport of the pans 25 from one station to the next or to the storage stations S multiple ways are provided, wherein the pans 25 can be transported on rails or by means of overhead cranes.

Die erfindungsgemässe Giessanlage ist mit einem Steuersystem ausgestattet, mit dem die aus einzelnen Ofen 22, 23, 24 in die einzelnen Pfannen 25 einzufüllenden Chargen, die Legierungszusätze, Heizung, Kühlung, Gaszufuhr und Behandlungszeiten gesteuert werden, damit die Aluschmelze in gewünschter Qualität, mit gewünschter Temperatur und voll homogenisiert zu den Giessstationen 33, 34 gelangt.The casting plant according to the invention is equipped with a control system with which the batches to be filled from individual ovens 22, 23, 24 into the individual pans 25, the alloying additions, heating, cooling, gas supply and treatment times are controlled so that the aluminum melt in the desired quality, with desired Temperature and fully homogenized to the Giessstationen 33, 34 passes.

Durch die erfindungsgemässe Verwendung von Pfannen 25 für das Behandeln und Zuführen von Aluschmelze in steuerbaren Sequenzen zu vorzugsweise mehreren Giessstationen 33, 34 wird diese Verfahrensphase von dem eigentlichen Giessvorgang zeitlich abgekoppelt. Die einzelnen Behandlungen sind nicht mehr fix festgelegt und zeitlich begrenzt, sondern sie können nach Bedarf angepasst werden, bis die gewünschte Qualität der zu vergiessenden Aluschmelze in der jeweiligen Pfanne erreicht wird. Wird z.B. ein niedriger Wasserstoffgehalt verlangt, kann die Gasreinigungszeit (degassing) verlängert werden. Diese Möglichkeit bestand bei dem traditionellen In-line-Verfahren nach Fig. 1 nicht. Die Produktionsleistung der Giessanlage hängt vom eigentlichen Giessprozess an den Giesstationen alleine ab, der fortgesetzt werden kann, bis die Zuführung der behandelten Aluschmelze zu den Giessstationen in gewollter Weise unterbrochen wird.By the inventive use of pans 25 for the treatment and feeding of Alauschmelze in controllable sequences to preferably several Giessstationen 33, 34, this process phase is decoupled from the actual casting process in time. The individual treatments are no longer fix fixed and limited in time, but they can be adjusted as needed, until the desired quality of the molten aluminum to be poured in the respective pan is achieved. If, for example, a low hydrogen content is required, the gas purification time ( degassing ) can be extended. This possibility existed in the traditional in-line method Fig. 1 Not. The production capacity of the casting plant depends on the actual casting process at the casting stations alone, which can be continued until the feed the treated Alauschmelze is interrupted to the Giessstationen in a desired manner.

Das erfindungsgemässe Verfahren ist wesentlich effizienter als das Inline-Verfahren, da die Notwendigkeit von grossen Wärmehalteofen entfällt. Wenn überhaupt, werden die Ofen zum Schmelzen und Aufheizen gebraucht, jedoch nicht zum Wärmehalten über längere Zeitabschnitte. Diese können als energetisch effiziente und ökologisch vorteilhafte Induktionsofen ausgebildet sein. Durch Vorheizen der Pfannen kann die in den Öfen erreichbare Temperatur der Schmelze eine tieferen Wert betragen.The inventive method is much more efficient than the inline method, since the need for large heat holding furnace is eliminated. If anything, the furnaces are needed for melting and heating, but not for keeping heat for long periods of time. These can be designed as an energetically efficient and ecologically advantageous induction furnace. By preheating the pans, the temperature of the melt which can be reached in the ovens can be a lower value.

Claims (19)

  1. Casting method for aluminium or aluminium alloys, in which molten aluminium is treated and fed to at least one casting station (33, 34), in which the molten aluminium is cast into semi-finished products or similar, characterised in that
    a number of ladles (25) are used to treat and to feed the molten aluminium to the respective casting station (33, 34), the melt being poured into said ladles, transported to a further stage (32) and treated there, and is then delivered to the casting station (33, 34), in which the ladles (25) are emptied.
  2. Casting method according to claim 1, characterised in that in a further stage (30) the emptied ladles (25) are cleaned and prepared for re-use, in particular are pre-heated.
  3. Casting method according to claim 1 or 2, characterised in that in the first stage (21) the melt is poured from one or alternatively from several furnaces (22, 23, 24) into the ladles (25), whereby if there are several furnaces (22, 23, 24) molten aluminium of varying quality from the individual furnaces (22, 23, 24) can be poured into the ladles (25).
  4. Casting method according to claim 3, characterised in that induction furnaces are used in the first stage (21).
  5. Casting methods according to one of the claims 1 to 4, characterised in that after filling the respective ladle (25), the slag is skimmed off the surface of the melting bath to which end the ladle is brought into a tilted position.
  6. Casting method according to one of the claims 1 to 5, characterised in that the second stage (32) includes the addition of alloying additions to the melt, their purification and homogenisation and also if necessary any temperature regulation.
  7. Casting method according to claim 6, characterised in that in the second treatment stage (32), the ladles (25) can be placed underneath an immersible rotary impeller to blow in argon or nitrogen for combined removal of hydrogen, homogenisation and if necessary, thermal regulation, whereby additional small amounts of chlorine can be mixed into the purge gas to remove alkali trace contaminants.
  8. Casting method according to one of the claims 2 to 7, characterised in that at least part of the alloy additions has been placed in the emptied and cleaned ladles (25) before the molten aluminium is poured in.
  9. Casting methods according to one of the claims 1 to 8, characterised in that the ladles (25) run through the individual stations or stages on rails or by means of overhead hoists, whereby multiple routes lead to preferably several casting stations (33, 34), and to additional storage stations (S) to store ladles (25) filled with molten aluminium and/or empty ones until use.
  10. Casting method according to one of the claims 1 to 9, characterised in that the emptying of the ladles (25) occurs at the respective casting station (33, 34) through the base of the ladles by controlled opening of a sliding closure, whereby the outflowing molten aluminium is guided into a collector spout preferably encased by an inert gas.
  11. Casting method according to one of the claims 6 to 10, characterised in that the filling of the ladles (25) with molten aluminium, if necessary with mixed material from various furnaces (22, 23, 24), the addition of the alloy additions, the homogenisation, the thermal regulation and chronological sequence of treatment and feeding of the molten aluminium to the selected casting station (33, 34), is computer-controlled.
  12. Casting method according to one of the claims 1 to 11, characterised in that the respective casting station (33, 34) operates continuously or semi-continuously and is equipped with a filter system.
  13. Casting machine to carry out the process according to claim 1, with at least one casting station (33, 34) and with means of treating and feeding molten aluminium to the casting station (33, 34), characterised in that the means of treating and feeding molten aluminium comprise a number of ladles (25) fillable in a first filling station (21) with the molten aluminium, which are transportable to a second treatment station (32) and from there to the respective casting station (33, 34), whereby multiple routes for the transport are provided, and the ladles (25) are each fitted with a sliding closure or similar, by the opening of which they can be emptied.
  14. Casting machine according to claim 13, characterised in that a further purification and preparation station (30) is provided for the emptied ladles (25), from which the ladles (25) are transportable to the filling station (21).
  15. Casting machine according to claim 13 or 14, characterised in that additional storage stations (S) are provided for storage of ladles (25) filled with molten aluminium and/or emptied ladles (25) until use.
  16. Casting machine according to one of the claims 13 to 15, characterised in that the filling station (21) is provided with a number of furnaces (22, 23, 24) which can be supplied with basic material, preferably induction furnaces, whereby the individual furnaces (22, 23, 24) can if necessary be supplied with aluminium material of varying quality.
  17. Casting machine according to one of the claims 13 to 16, characterised in that the ladles (25) can be covered by a cover in which a burner can be installed to maintain or to increase the temperature of the molten aluminium.
  18. Casting machine according to one of the claims 13 to 17, characterised in that the ladles (25) are equipped with a porous plug for injection of an inert gas.
  19. Casting machine according to one of the claims 13 to 18, characterised in that rails or hoists are provided for the transport of the ladles (25) from one station to the next and to the storage stations (S).
EP04405366A 2004-06-16 2004-06-16 Casting method and installation for casting aluminium or aluminium alloys Not-in-force EP1607156B1 (en)

Priority Applications (12)

Application Number Priority Date Filing Date Title
AT04405366T ATE421398T1 (en) 2004-06-16 2004-06-16 CASTING PROCESS AND CASTING SYSTEM FOR ALUMINUM OR ALUMINUM ALLOYS
EP04405366A EP1607156B1 (en) 2004-06-16 2004-06-16 Casting method and installation for casting aluminium or aluminium alloys
DE502004008913T DE502004008913D1 (en) 2004-06-16 2004-06-16 Casting and casting plant for aluminum or aluminum alloys
CNA2005800198473A CN1976773A (en) 2004-06-16 2005-06-16 Casting method and installation for casting aluminium or aluminium alloys
CA002570361A CA2570361A1 (en) 2004-06-16 2005-06-16 Casting method and casting installation for aluminium or aluminium alloys
RU2007101384/02A RU2007101384A (en) 2004-06-16 2005-06-16 METHOD FOR CASTING AND INSTALLATION FOR CASTING OF ALUMINUM OR ALUMINUM ALLOYS
US11/629,712 US20080164000A1 (en) 2004-06-16 2005-06-16 Casting Method and Casting Installation for Aluminium or Aluminium Alloys
PCT/EP2005/006486 WO2005123304A2 (en) 2004-06-16 2005-06-16 Casting method and casting installation for aluminium or aluminium alloys
AU2005254220A AU2005254220A1 (en) 2004-06-16 2005-06-16 Casting method and casting installation for aluminium or aluminium alloys
MXPA06014600A MXPA06014600A (en) 2004-06-16 2005-06-16 Casting method and casting installation for aluminium or aluminium alloys.
JP2007515884A JP2008502483A (en) 2004-06-16 2005-06-16 Aluminum and / or aluminum alloy casting method and facility
ZA200609947A ZA200609947B (en) 2004-06-16 2006-11-28 Casting method and casting installation for aluminium or aluminium alloys

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
EP04405366A EP1607156B1 (en) 2004-06-16 2004-06-16 Casting method and installation for casting aluminium or aluminium alloys

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EP1607156A1 EP1607156A1 (en) 2005-12-21
EP1607156B1 true EP1607156B1 (en) 2009-01-21

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EP (1) EP1607156B1 (en)
JP (1) JP2008502483A (en)
CN (1) CN1976773A (en)
AT (1) ATE421398T1 (en)
AU (1) AU2005254220A1 (en)
CA (1) CA2570361A1 (en)
DE (1) DE502004008913D1 (en)
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RU (1) RU2007101384A (en)
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US20100132913A1 (en) * 2007-04-16 2010-06-03 Pierre Gerber Casting Method and Casting System for Aluminium or Aluminium Alloys
CN102151816B (en) * 2011-03-10 2013-04-24 山东滨州渤海活塞股份有限公司 Automatic aluminum piston casting machine
CN104259396A (en) * 2014-07-10 2015-01-07 陕西国德电气制造有限公司 Manufacturing method for corbel
CN115213393B (en) * 2022-07-09 2023-07-21 江苏政田新材料有限公司 Molten steel filtering device for casting anchor chain wheel

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GB8428251D0 (en) * 1984-11-08 1984-12-19 Alcan Int Ltd Treating aluminium
US4959101A (en) * 1987-06-29 1990-09-25 Aga Ab Process for degassing aluminum melts with sulfur hexafluoride
DE3736117A1 (en) 1987-10-26 1989-05-03 Krupp Gmbh PLANT FOR THE PRODUCTION OF STEEL, IN PARTICULAR MINI STEEL PLANT
US5272720A (en) * 1990-01-31 1993-12-21 Inductotherm Corp. Induction heating apparatus and method
JPH09182958A (en) * 1995-12-28 1997-07-15 Kusano Sangyo Kk Device for automatically transporting molten metal ladle
JP3680252B2 (en) * 1999-06-29 2005-08-10 Ｊｆｅスチール株式会社 How to use a regenerative burner
JP3621405B2 (en) * 2000-12-27 2005-02-16 株式会社豊栄商会 container
JP3323489B1 (en) * 2000-12-27 2002-09-09 株式会社豊栄商会 Container for supplying molten metal
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RU2007101384A (en) 2008-07-27
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ZA200609947B (en) 2008-11-26
WO2005123304A3 (en) 2006-08-10
JP2008502483A (en) 2008-01-31
ATE421398T1 (en) 2009-02-15
CA2570361A1 (en) 2005-12-29
MXPA06014600A (en) 2007-05-16
AU2005254220A1 (en) 2005-12-29
DE502004008913D1 (en) 2009-03-12
EP1607156A1 (en) 2005-12-21
CN1976773A (en) 2007-06-06

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