KR20140091213A - Apparatus and method for manufacturing aluminium alloy ingot - Google Patents

Abstract

According to the present invention, a method for manufacturing an aluminum alloy ingot comprises the steps of forming molten aluminum in a first furnace; tapping the molten aluminum from the first furnace into a second furnace; forming molten aluminum alloy by adding an alloy additive into the second furnace; degassing and stirring the molten aluminum alloy in the second furnace; stabilizing the molten aluminum processed by the degassing step in the second furnace; and tapping the molten aluminum into an ingot mold.

Description

BACKGROUND OF THE INVENTION 1. Field of the Invention [0001] The present invention relates to an aluminum alloy ingot manufacturing apparatus,

The present invention relates to an aluminum alloy ingot manufacturing apparatus and a manufacturing method thereof, and more particularly, to an apparatus and a method for manufacturing an aluminum alloy ingot that performs die casting and anodizing.

BACKGROUND ART [0002] With the recent development of the electronic communication industry, portable electronic devices, for example, portable information terminals such as mobile phones, notebooks, and PDAs that can be carried by individuals are widely spreading. Such portable electronic devices are becoming increasingly interested in the upgrading of interior and exterior materials such as cases, frames, brackets, and the like due to competition of light and small size designs of products.

BACKGROUND ART [0002] In recent years, a thin die-cast aluminum alloy casing has been researched and developed as a casing of a portable electronic device. Die casting aluminum alloy case can express various colors without coloring process by coloring process after surface anodizing. The surface gloss and color quality of the die cast aluminum alloy case are greatly affected by the aluminum alloy composition ratio.

Therefore, it is very important to control the composition ratio of aluminum alloy in order to express excellent gloss and color.

Typically, the manufacturing process of the outer case of the die-casting portable electronic device comprises an aluminum alloy melting process, a die casting process, an anodizing process, and a coloring process.

Here, in the aluminum alloy melting process, aluminum and alloy additives are dissolved in an electric furnace to form an aluminum alloy melt, and the formed aluminum alloy melt is injected into a die casting mold at a high pressure and a high speed to form a matrix of an outer case.

The conventional aluminum alloy melting process consumes a lot of time and energy, and it is difficult to control various alloy composition ratios and productivity is low.

Alternatively, there may be a method in which an aluminum alloy ingot is prepared by previously mixing an aluminum alloy in a large-capacity melting furnace at an aluminum ingot production factory and then dissolving it in a preserving furnace for die casting. In this case, since the alloy additive is mixed in a large-capacity melting furnace, it is difficult to ensure the uniformity of the compositional components of many aluminum alloy ingots.

It is an object of the present invention to provide an aluminum alloy ingot manufacturing apparatus and method of manufacturing an aluminum alloy ingot which can easily control uniformity of an alloy composition and produce an aluminum alloy ingot with a high composition ratio.

Another object of the present invention is to provide an aluminum alloy ingot manufacturing apparatus and a manufacturing method thereof capable of obtaining an energy saving effect by efficient use of energy.

It is still another object of the present invention to provide an aluminum alloy ingot manufacturing apparatus which can be continuously produced semi-automatically or automatically, and a manufacturing method thereof.

A method of manufacturing an aluminum alloy ingot according to an embodiment for realizing the object of the present invention is characterized in that an aluminum molten metal is formed in a first melting furnace, molten aluminum is melted in a second melting furnace, Adding an additive to form an aluminum alloy melt, degassing and stirring the molten aluminum alloy in the second melting furnace, stabilizing the molten aluminum after degassing in the second melting furnace, and then tapping the molten aluminum melt in the ingot casting mold do.

In the embodiment, it is preferable that the second melting furnace has a small capacity of less than 1 ton and the first melting furnace has a large capacity larger than that of the second melting furnace. This is because uniform mixing of aluminum and alloy additives is better in the second melting furnace of small capacity than in the first melting furnace of large capacity.

의 용융 온도를 유지하는 전기로이고 제1용해로는 평균 800

의 용융 온도를 유지하는 반사로로 구성하는 것이 에너지 사용의 효율성 면에서 유리하다. In an embodiment, the second furnace has an average of 750

And the first melting furnace has an average of 800

It is advantageous from the viewpoint of efficiency of energy use.

In an embodiment, the second melting furnace includes at least two or more electric furnaces of the same capacity, and each of the at least two electric furnaces is provided with different stages of the alloy melting step, the degassing and stirring step or the tapping step at the same time Thereby making it possible to produce an aluminum alloy ingot having a multi-composition ratio and to improve production efficiency.

In the embodiment, it is possible to improve the ingot production efficiency by performing the degassing, stirring, and tapping steps in the other electric furnaces while performing the alloy melting step in one of the at least two electric furnaces.

In an embodiment, each of the at least two electric furnaces each include a different alloy additive, which enables ingot production with a multi-composition ratio.

In the examples, the alloy additive contains 1.0 to 5.0% by weight of Mn, 0.5 to 1.5% by weight of Zn, 1.0 to 2.0% by weight of Zr and 0.5 to 1.5% by weight of Cu, contributing to the production of high quality products in the die- do. The alloy additive preferably further comprises 0.1 to 0.6% by weight of Si, 0.5 to 1.5% by weight of Fe, 2% by weight or less of Ni, 0.5 to 1% by weight of Mg and 0.3 to 0.7% by weight of Ti.

An aluminum alloy ingot manufacturing apparatus according to an embodiment of the present invention includes a large-capacity aluminum melting furnace for forming molten aluminum and three electric furnaces on one turntable. The molten aluminum from the aluminum melting furnace is supplied to three electric furnaces A small-capacity alloy melting furnace which is sequentially supplied with aluminum alloy melt by adding an alloy additive to each of the electric furnaces, and a ladle furnace for pouring the aluminum alloy melt from one of the three electric furnaces into a plurality of aluminum alloy ingot molds, And a transfer device for transferring the aluminum alloy ingot by mounting a plurality of aluminum alloy ingot molds on an endless track. Such a structure enables the realization of a semiautomatic or electromechanical plant for continuous ingot production and contributes to productivity improvement.

In the manufacturing apparatus of the embodiment, it is preferable that a degassing and stirring machine is coupled to one of the three electric furnaces.

According to the present invention, an aluminum alloy ingot manufacturing method and apparatus are capable of continuously producing molten aluminum in a melting furnace of a large capacity and tapping the produced molten metal into a small-capacity electric furnace to add an alloy additive therein to form an aluminum alloy melt, It is possible to obtain an ornamental surface effect of excellent exterior material in a post-process, that is, high quality of gloss and color.

In addition, since it is easy to control the composition ratio, it is possible to produce a small variety of ingot with a multi-composition ratio, and it is possible to achieve productivity improvement and energy saving effect by enabling semi-

1 is a plan view of an apparatus for producing an aluminum alloy ingot according to an embodiment of the present invention;
2 is a side view of an apparatus for producing an aluminum alloy ingot of Fig. 1; Fig.
Fig. 3 is an external perspective view of a preferred embodiment of the first melting furnace of the aluminum alloy ingot manufacturing apparatus of Fig. 1; Fig.
Fig. 4 is a timing chart showing the operation timing of the aluminum alloy ingot manufacturing apparatus shown in Fig.

Hereinafter, preferred embodiments of the present invention will be described in more detail with reference to the drawings. The present invention is capable of various modifications and various forms, and specific embodiments are illustrated in the drawings and described in detail in the text. It is to be understood, however, that the invention is not intended to be limited to the particular forms disclosed, but on the contrary, is intended to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention. Like reference numerals are used for like elements in describing each drawing. In the accompanying drawings, the dimensions of the structures are enlarged to illustrate the present invention in order to clarify the present invention. The terms first, second, etc. may be used to describe various components, but the components should not be limited by the terms. The terms are used only for the purpose of distinguishing one component from another. For example, without departing from the scope of the present invention, the first component may be referred to as a second component, and similarly, the second component may also be referred to as a first component. The singular expressions include plural expressions unless the context clearly dictates otherwise.

In this application, the terms "comprises", "having", and the like are used to specify that a feature, a number, a step, an operation, an element, a part or a combination thereof is described in the specification, But do not preclude the presence or addition of one or more other features, integers, steps, operations, components, parts, or combinations thereof.

 FIG. 1 is a plan view of an apparatus for producing an aluminum alloy ingot according to an embodiment of the present invention, FIG. 2 is a side view of the apparatus for manufacturing an aluminum alloy ingot of FIG. 1, 1 is a perspective view of a preferred embodiment of a melting furnace.

Referring to the drawings, an aluminum alloy ingot manufacturing apparatus 100 according to an embodiment of the present invention includes an aluminum melting furnace 110, an alloy melting furnace 120, a ladle machine 130, and a feeder 140.

(~최대 850

) 이상으로 가열하여 99.9%의 알루미늄 잉곳을 용융해서 알루미늄 용탕을 형성한다. 형성된 알루미늄 용탕은 출탕구(113)에 연결된 출탕관(112)을 통해 합금 용해로(120)로 낙하된다. 알루미늄 잉곳은 엘리베이터(116)를 통해 노(111)의 잉곳 투입구(115)를 통해 노(111) 내부로 투입된다. Referring to FIG. 3, the aluminum melting furnace 110 includes a reflection furnace 111 having a large capacity for forming aluminum molten metal, for example, a capacity of 1 ton or more, and preferably 2.5 ton. The aluminum melting furnace 110 uses an LNG gas burner 114 to heat the inside of the furnace 111 to an average of 800

(~ 850 max

) To melt aluminum ingots of 99.9% to form molten aluminum. The formed molten aluminum is dropped onto the alloy melting furnace 120 through the outlet pipe 112 connected to the tapping tunnel 113. The aluminum ingot is injected into the furnace 111 through the elevator 116 through the ingot inlet 115 of the furnace 111.

(최대 800

) 이상으로 가열하여 99.9%의 알루미늄 용탕 내에 합금 첨가물을 추가해서 소정의 합금 조성비를 가진 알루미늄 합금 용탕을 형성한다. The alloy melting furnace 120 has three electric rods EF1, EF2 and EF3 mounted on one turntable 122. The electric furnaces EF1, EF2 and EF3 are rotated by the rotation of the turntable 122 to stabilize the position of the molten aluminum in the molten metal injection position (EF1 position in Fig. 1), degassing and stirring position (EF2 position in Fig. Position (position EF3 in Fig. 1). Each of the electric furnaces EF1, EF2, and EF3 has a small capacity, for example, a capacity of 650 kg, for example, an average 750

(Up to 800

) To add an alloy additive in a molten aluminum of 99.9% to form an aluminum alloy melt having a predetermined alloy composition ratio.

(최대 850

) 이상으로 가열하여 알루미늄 합금 용탕을 형성한다. 여기서 전기로들(EF1, EF2, EF3) 각각에 추가되는 합금 첨가물의 조성 성분은 잉곳 설계에 따라 동일하게 하거나 서로 다르게 할 수 있다. 여기서 합금 첨가물은 상술한 예시 조성성분들로 한정되는 것이 아니라 다양한 조성성분들, 예컨대 Co, Sr, V 등을 포함할 수도 있다. At the aluminum molten metal injection position (EF1 position in Fig. 1), for example, 500 kg of molten aluminum is injected. Wherein an alloy additive such as 1.0 to 5.0 wt% of Mn, 0.5 to 1.5 wt% of Zn, 1.0 to 2.0 wt% of Zr, 0.5 to 1.5 wt% of Cu, 0.1 to 0.6 wt% of Si, 0.5 to 1.5 wt% of Fe, Ni 2 By weight or less, 0.5 to 1% by weight of Mg, 0.3 to 0.7% by weight of Ti, etc., and then 800

(Up to 850

) Or more to form an aluminum alloy molten metal. Here, the composition components of the alloy additions added to each of the electric furnaces EF1, EF2, and EF3 may be the same or different depending on the ingot design. Here, the alloy additive is not limited to the above-exemplified composition components but may include various composition components such as Co, Sr, V, and the like.

In the degassing and agitation position (EF2 position in FIG. 1), the electric furnace EF2 is combined with the degassing and stirring machine 124. The degassing step is a step of removing hydrogen gas in the molten metal. Hydrogen gas is generated from hydrogen, water, and other organic substances in the fuel. When a large amount of hydrogen gas is contained, pin casting may occur in the aluminum ingot by die casting, or the strength of the product may be weakened. Removal of the hydrogen gas in the dehydrogenation gas process can be preferably performed by performing fluxing, chlorine refining, or in-line refining. However, when the degassing and stirring machine 124 is subjected to a sniff or porous plug, can do.

In the stabilization and ingot casting position (EF3 position in FIG. 1), the stirred molten metal is stabilized for 20 to 30 minutes, for example, and the molten metal is stored and maintained at a temperature most suitable for casting.

The ladle machine 130 performs a process of pouring the molten metal in the electric furnace EF3 into the ingot casting mold 142 of the transfer device 140 by pouring the molten metal into the ladle 132 having a capacity of, for example, 5 kg. The ladle machine 130 pushes the oxide covering the surface of the electric furnace EF3 to the outer circumferential surface of the ladle 132 and stores the exposed aluminum alloy melt in the ladle 132. [ The molten aluminum alloy contained in the ladle 132 is injected into the ingot casting mold 142 through a funnel-shaped induction pipe 144.

The transfer device 140 has a plurality of ingot casting molds 142 mounted on an endless track and is conveyed at a constant speed by the operation of the conveying motor. The conveying length of the conveying device 140 is long enough that the aluminum alloy ingot in the ingot casting mold 142 is cooled and solidified by natural cooling during the transfer. At the end of the transfer device 140, a rectangular 5 kg aluminum alloy ingot is obtained.

Therefore, 500kg of molten metal can produce 100kg of 5kg aluminum alloy ingot.

Here, the numerical values are illustrative and not restrictive. By varying the capacity of the electric furnace and the capacity design of the ingot casting mold 142, ingots of various sizes can be produced.

Fig. 4 is a timing chart of operation of the instant embodiment of the aluminum alloy ingot manufacturing apparatus shown in Fig. 1; Fig.

4, at time t0, the molten aluminum is supplied to the electric furnace EF1 from the large reflection furnace 110 and the parent alloy is added to the molten aluminum in the electric furnace EF1 and heated to form an aluminum alloy Thereby forming a molten metal. At the time t1, the turntable 122 is rotated 1/3 and then the molten aluminum is introduced into the electric furnace EF2 from the large reflecting furnace 110 and the mother alloy, that is, the alloy additive is added into the molten aluminum of the electric furnace EF2 And then heated to form an aluminum alloy melt. At the time t2, the turntable 122 is rotated 1/3 and then the molten aluminum is introduced into the electric furnace EF3 from the large reflecting furnace 110 and the mother alloy, that is, the alloy additive is added into the molten aluminum of the electric furnace EF3 And then heated to form an aluminum alloy melt.

At the time t3, the turntable 122 is rotated to place the position of the electric furnace EF1 at the degassing agitation position, and then the degassing machine 124 removes hydrogen from the aluminum alloy melt in the electric furnace EF1, .

The turntable 122 is rotated at time t4 to position the electric furnace EF1 at the casting position and then pouring the aluminum alloy melt into the ingot casting mold 142 using the ladle machine 130 to cast the alloy ingot do. The cast aluminum alloy ingot is conveyed through the conveying device 140 while being contained in the ingot casting frame 142. At the same time, the degassing machine 124 removes hydrogen from the molten aluminum alloy in the electric furnace EF2 and stirs it. In the electric furnace (EF3), the aluminum alloy melting process is maintained.

The turntable 122 is rotated 1/3 to move the position of the electric furnace EF1 to the melting position at time t5 and then the molten aluminum is discharged from the large reflecting furnace 110 to the electric furnace EF1, ) Is added to the molten aluminum in the molten aluminum, that is, the alloy additive is added and heated to form the molten aluminum alloy. At the same time, in the electric furnace EF2 located at the casting position, an aluminum alloy melt is poured into the ingot casting mold 142 using the ladle machine 130 to cast an alloy ingot. The cast aluminum alloy ingot is conveyed through the conveying device 140 while being contained in the ingot casting frame 142. Further, hydrogen is removed from the molten aluminum alloy in the electric furnace EF3 by the degassing machine 124 and stirred.

The turntable 122 is rotated 1/3 at time t6 to position the electric furnace EF2 at the melting position and then the molten aluminum is discharged from the large reflection furnace 110 to the electric furnace EF2 and the electric furnace EF2 ) Is added to the molten aluminum in the molten aluminum, that is, the alloy additive is added and heated to form the molten aluminum alloy. At the same time, in the electric furnace EF3 located at the casting position, an aluminum alloy melt is poured into the ingot casting mold 142 using the ladle machine 130 to cast an alloy ingot. The cast aluminum alloy ingot is conveyed through the conveying device 140 while being contained in the ingot casting frame 142. In the electric furnace (EF1), the aluminum alloy melting process is maintained.

The turntable 122 is rotated 1/3 at time t7 to position the electric furnace EF3 at the melting position and then the molten aluminum is discharged from the large reflection furnace 110 to the electric furnace EF3, ) Is added to the molten aluminum in the molten aluminum, that is, the alloy additive is added and heated to form the molten aluminum alloy. In the electric furnaces EF1 and EF2, the aluminum alloy melting process is maintained.

Thus, aluminum alloy ingots are sequentially manufactured for one cycle from time t0 to t7. Preferably, the alloy melting process is controlled for 3 hours, the casting and degassing process is controlled for 1 hour, and the 4-cycle production process is possible for 24 hours a day.

1.5 tons per cycle, that is, aluminum alloy ingot production is possible, so it is possible to continuously produce 6 tons of aluminum alloy ingot per day.

According to the embodiment of the present invention described above, since aluminum alloy ingots can be continuously produced and three electric furnaces can be used, it is possible to produce aluminum alloy ingots having different alloy composition ratios in the simultaneous continuous process, Therefore, it is possible to produce a small quantity of various kinds of products according to demand in a continuous process, which can greatly improve the productivity.

INDUSTRIAL APPLICABILITY The present invention makes it possible to produce various kinds of aluminum alloy ingots in a small quantity by a continuous process. Therefore, aluminum alloy ingots having various composition ratios can be efficiently supplied.

It will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the spirit or scope of the present invention as defined by the following claims. You will understand.

Claims (12)

Forming an aluminum molten metal in the first melting furnace;
Tapping the molten aluminum of the first melting furnace into the second melting furnace;
Adding an alloyed additive in a second melting furnace to form an aluminum alloy melt;
Degassing and stirring the aluminum alloy melt in the second melting furnace;
And a step of tapping an aluminum molten metal subjected to degassing treatment in the second melting furnace to an ingot casting mold. The method of manufacturing an aluminum alloy ingot according to claim 1, wherein the second melting furnace has a small capacity of less than 1 ton, and the first melting furnace has a large capacity larger than that of the second melting furnace. The method of claim 1, wherein the second melting furnace has an average of 750

And the first melting furnace has an average of 800

Of the aluminum alloy ingot. 2. The method according to claim 1, wherein the second melting furnace comprises at least two electric furnaces of the same capacity, and each of the at least two electric furnaces is different in the alloy melting step, the degassing and stirring step or the casting step Wherein the step of forming the aluminum alloy ingot comprises the steps of: 5. The method of manufacturing an aluminum alloy ingot according to claim 4, wherein the degassing and stirring step and the tapping step are performed in the other electric furnaces while performing the alloy melting step in one of the at least two electric paths . 2. The method of claim 1, wherein each of the at least two electric furnaces further comprises a different alloy additive. 7. The method according to claim 6, wherein the alloy additive comprises 1.0 to 5.0% by weight of Mn, 0.5 to 1.5% by weight of Zn, 1.0 to 2.0% by weight of Zr and 0.5 to 1.5% by weight of Cu. 8. The method of claim 7, wherein the alloy additive further comprises 0.1 to 0.6 wt% of Si, 0.5 to 1.5 wt% of Fe, 2 wt% or less of Ni, 0.5 to 1 wt% of Mg, and 0.3 to 0.7 wt% Wherein the aluminum alloy ingot is produced by a method comprising: A large-capacity aluminum melting furnace for forming molten aluminum;
A plurality of electric furnaces are provided on one turntable and the molten aluminum molten from the aluminum melting furnace is sequentially supplied to each of the three electric furnaces and an alloyed additive is added to each of the electric furnaces to form a molten aluminum alloy melt Alloy melting furnace;
A ladle machine for pouring the aluminum alloy melt from one of the three electric furnaces into a plurality of aluminum alloy ingot casting molds; And
Wherein the plurality of aluminum alloy ingot molds are mounted on an endless track and are provided with a transfer device for transferring the aluminum alloy ingot. 10. The apparatus according to claim 9, wherein the manufacturing apparatus
And a degassing and stirring machine is coupled to any one of the three electric furnaces. 10. The apparatus according to claim 9, wherein the manufacturing apparatus
And the alloy additions added to each of the three electric rods are different from each other. 10. The apparatus according to claim 9, wherein the manufacturing apparatus
Wherein one of the three electric furnaces performs an alloy melting process and the remaining electric furnaces perform a degassing and stirring process or a tapping process.

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