US20050029718A1 - Filtration system for magnesium recycling and purification - Google Patents
Filtration system for magnesium recycling and purification Download PDFInfo
- Publication number
- US20050029718A1 US20050029718A1 US10/493,006 US49300604A US2005029718A1 US 20050029718 A1 US20050029718 A1 US 20050029718A1 US 49300604 A US49300604 A US 49300604A US 2005029718 A1 US2005029718 A1 US 2005029718A1
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- chamber
- magnesium
- magnesium melt
- filter
- melt
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- Abandoned
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- 239000011777 magnesium Substances 0.000 title claims abstract description 131
- 229910052749 magnesium Inorganic materials 0.000 title claims abstract description 126
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 title claims abstract description 125
- 238000001914 filtration Methods 0.000 title claims description 49
- 238000000746 purification Methods 0.000 title claims description 8
- 238000004064 recycling Methods 0.000 title claims description 8
- 239000012535 impurity Substances 0.000 claims abstract description 24
- 238000004512 die casting Methods 0.000 claims abstract description 11
- 230000001681 protective effect Effects 0.000 claims abstract description 8
- 238000010438 heat treatment Methods 0.000 claims description 16
- 238000004891 communication Methods 0.000 claims description 6
- 239000012530 fluid Substances 0.000 claims description 6
- CPLXHLVBOLITMK-UHFFFAOYSA-N Magnesium oxide Chemical compound [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 claims description 5
- 230000002463 transducing effect Effects 0.000 claims description 5
- 229910000831 Steel Inorganic materials 0.000 claims description 4
- 239000000463 material Substances 0.000 claims description 4
- 239000010959 steel Substances 0.000 claims description 4
- 229910010293 ceramic material Inorganic materials 0.000 claims description 3
- 230000008018 melting Effects 0.000 claims description 3
- 238000002844 melting Methods 0.000 claims description 3
- 238000013021 overheating Methods 0.000 claims description 3
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims description 2
- 229910000147 aluminium phosphate Inorganic materials 0.000 claims description 2
- 229910052593 corundum Inorganic materials 0.000 claims description 2
- 239000007787 solid Substances 0.000 claims description 2
- 229910001845 yogo sapphire Inorganic materials 0.000 claims description 2
- 239000007789 gas Substances 0.000 claims 5
- RTZKZFJDLAIYFH-UHFFFAOYSA-N Diethyl ether Chemical compound CCOCC RTZKZFJDLAIYFH-UHFFFAOYSA-N 0.000 claims 2
- 230000001276 controlling effect Effects 0.000 claims 2
- 239000000395 magnesium oxide Substances 0.000 claims 2
- 230000001105 regulatory effect Effects 0.000 claims 1
- 229910000861 Mg alloy Inorganic materials 0.000 abstract description 12
- 238000005266 casting Methods 0.000 abstract description 10
- 238000000034 method Methods 0.000 abstract description 5
- 230000002411 adverse Effects 0.000 abstract description 2
- 230000007547 defect Effects 0.000 abstract description 2
- 238000002360 preparation method Methods 0.000 abstract description 2
- 238000012360 testing method Methods 0.000 description 7
- 239000000155 melt Substances 0.000 description 5
- 239000010802 sludge Substances 0.000 description 5
- 229910045601 alloy Inorganic materials 0.000 description 4
- 239000000956 alloy Substances 0.000 description 4
- 238000001000 micrograph Methods 0.000 description 4
- 230000036961 partial effect Effects 0.000 description 4
- 238000009864 tensile test Methods 0.000 description 4
- 239000000203 mixture Substances 0.000 description 3
- 230000002829 reductive effect Effects 0.000 description 3
- 238000003723 Smelting Methods 0.000 description 2
- 230000002706 hydrostatic effect Effects 0.000 description 2
- 229910000765 intermetallic Inorganic materials 0.000 description 2
- 230000003287 optical effect Effects 0.000 description 2
- 239000002210 silicon-based material Substances 0.000 description 2
- 229910000838 Al alloy Inorganic materials 0.000 description 1
- 244000261422 Lysimachia clethroides Species 0.000 description 1
- 238000004458 analytical method Methods 0.000 description 1
- 238000011109 contamination Methods 0.000 description 1
- 229910052802 copper Inorganic materials 0.000 description 1
- 230000003247 decreasing effect Effects 0.000 description 1
- 230000005496 eutectics Effects 0.000 description 1
- 229910052742 iron Inorganic materials 0.000 description 1
- 229910052748 manganese Inorganic materials 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 229910052759 nickel Inorganic materials 0.000 description 1
- 238000000399 optical microscopy Methods 0.000 description 1
- 239000002245 particle Substances 0.000 description 1
- 239000002244 precipitate Substances 0.000 description 1
- 238000007712 rapid solidification Methods 0.000 description 1
- 229910052710 silicon Inorganic materials 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 229910052725 zinc Inorganic materials 0.000 description 1
Images
Classifications
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22B—PRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
- C22B26/00—Obtaining alkali, alkaline earth metals or magnesium
- C22B26/20—Obtaining alkaline earth metals or magnesium
- C22B26/22—Obtaining magnesium
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D17/00—Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
- B22D17/20—Accessories: Details
- B22D17/30—Accessories for supplying molten metal, e.g. in rations
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D43/00—Mechanical cleaning, e.g. skimming of molten metals
- B22D43/001—Retaining slag during pouring molten metal
- B22D43/004—Retaining slag during pouring molten metal by using filtering means
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22B—PRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
- C22B9/00—General processes of refining or remelting of metals; Apparatus for electroslag or arc remelting of metals
- C22B9/006—General processes of refining or remelting of metals; Apparatus for electroslag or arc remelting of metals with use of an inert protective material including the use of an inert gas
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22B—PRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
- C22B9/00—General processes of refining or remelting of metals; Apparatus for electroslag or arc remelting of metals
- C22B9/02—Refining by liquating, filtering, centrifuging, distilling, or supersonic wave action including acoustic waves
- C22B9/023—By filtering
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P10/00—Technologies related to metal processing
- Y02P10/20—Recycling
Definitions
- the present invention relates generally to a filtration system for purifying magnesium. Specifically, the present invention relates to a filtration system for recycling and purification of scrap magnesium and magnesium ingots with impurities.
- Magnesium alloys are heated to a molten state in preparation for hot-working thereof. Molten magnesium alloys easily oxidise and react with impurities, especially when scrap magnesium alloys are reused. As a result, magnesium alloys are contaminated by non-metallic and metallic inclusions, for example oxides or intermetallic compounds, when melted.
- the magnesium alloys are typically melted for producing castings.
- the presence of inclusions within the magnesium alloys results in metallurgical defects therein and will adversely affect the quality of the castings produced from the magnesium alloys.
- a known method for removing the impurities is to send the magnesium alloys to a smelter for smelting.
- smelting is a costly process.
- Another known process uses impediment plates disposed within a furnace for removing top and bottom sludge from magnesium melts.
- the impediment plates do not remove inclusions suspended in the magnesium melts.
- a filtration system for magnesium recycling and purification comprising:
- a filtration method for magnesium recycling and purification comprising the steps of:
- a filtration method for magnesium recycling and purification comprising the steps of:
- FIG. 1 shows a partial front sectional view of a filtration system according to an embodiment of the invention
- FIG. 2 shows a partial side sectional view of the filtration system of FIG. 1 ;
- FIG. 3 is an illustration of a filter of the filtration system of FIG. 1 ;
- FIG. 4 is an illustration of a first chamber and the filter of FIG. 3 ;
- FIG. 5 a shows a low magnification light optical microscope (LOM) micrograph of a tensile specimen made from magnesium melt obtained from the filtration system of FIG. 1 ;
- LOM low magnification light optical microscope
- FIG. 5 b shows the LOM micrograph of FIG. 5 a under high magnification
- FIG. 6 a shows a low magnification light optical microscope (LOM) micrograph of a mobile phone case specimen made from magnesium melt obtained from the filtration system of FIG. 1 ;
- LOM low magnification light optical microscope
- FIG. 6 b shows the LOM micrograph of FIG. 6 b under high magnification
- FIG. 7 a shows a graph plotting the tensile strength (ultimate tensile strength and yield strength) of test samples as a function of cross-head speed with the test samples being cast from a magnesium melt purified using the filtration system of FIG. 1 ;
- FIG. 7 b shows a graph plotting the percentage elongation of the test samples of FIG. 7 b , as a function of cross-head speed.
- FIG. 1 shows a partial front sectional view of the filtration system 20
- FIG. 2 shows a partial side sectional view of the filtration system 20 .
- the filtration system 20 is for use in substantially purifying magnesium.
- the filtration system 20 includes a crucible 22 being divided into two parts by a filter adapter 24 disposed therein, the two parts of the crucible being namely a first chamber 26 and a second chamber 28 .
- the first chamber 26 is in fluid communication with the second chamber 28 through an opening 30 , as shown in FIG. 2 , in the filter adapter 24 that forms a passageway therebetween.
- the filter adapter 24 is for receiving a filter 32 therewithin and for removably engaging thereto.
- FIG. 3 is an illustration of the filter 32
- FIG. 4 is an illustration of the first chamber 26 and the filter 32 .
- the filter adapter 24 is preferably a steel structure that shaped and dimensioned for holding the filter 32 at the periphery thereof.
- the filtration system 20 further includes a heating apparatus coupled to the crucible 22 .
- the heating apparatus is preferably integrated with the crucible 22 for providing heat to the crucible 22 and its contents.
- the heating apparatus is electrically connected to a controller (all not shown).
- the filtration system 20 is for providing substantially purified magnesium melts to downstream systems or machineries, for example, a die-casting machine.
- magnesium ingots or scraps are provided to the first chamber 26 of the filtration system 20 .
- the controller activates the heating apparatus to provide heat to the crucible 22 and the magnesium therein, thereby melting the magnesium.
- magnesium melt can be provided to the first chamber 26 of the crucible 22 .
- the heating apparatus provides heat to the crucible 22 to maintain the magnesium melt in its molten state and to melt the magnesium scraps and ingots added to the magnesium melt thereafter.
- the filter 32 of the filtration system 20 is preferably made of a silicon-free material.
- Conventional filters for example a filter for aluminium alloys, are made of silicon-based materials. The silicon-based materials readily react with magnesium to cause contamination therein and are therefore undesirable.
- the filter 32 is made of one of steels or ceramic material which comprises of one or more material selected from a group consisting of Al 2 O 3 , MgO, AlPO 4 and Mg 3 (PO 4 ) 2 .
- the filter 32 comprises of an array of apertures (not shown). Each of the apertures is shaped and dimensioned for preventing the passage of a particle having a size greater than 5 microns therethrough. Preferably, each pair of adjacent apertures are spaced apart a distance of 5 to 250 microns.
- the magnesium melt 38 in the first chamber 26 passes through the filter 32 and into the second chamber 28 of the crucible 22 . Therefore, the impurities suspended in the magnesium melt 38 contained in the first chamber 26 is substantially removed by the filter 32 before entering the second chamber 28 as purified magnesium melt 40 .
- the magnesium melt 38 contained in the first chamber 26 contains bottom sludge that has settled at the bottom of the first chamber 26 .
- top sludge can also be found floating at the surface of the magnesium melt 38 contained in the first chamber 26 .
- the filter adapter 24 functions to substantially impede the top sludge and bottom sludge in the first chamber 26 from entering the second chamber 28 (all not shown).
- the magnesium melt 38 in the first chamber 26 is drawn into the second chamber 28 by hydrostatic forces acting on the magnesium melt 38 .
- the magnesium melt 38 in the first chamber 26 continues to be drawn into the second chamber until the hydrostatic pressures of magnesium melt 38 in the first chamber 26 and the purified magnesium melt 40 in the second chamber 28 are in equilibrium.
- each of the first chamber 26 and the second chamber 28 has a thermocouple 42 disposed therewithin. Both the thermocouples 42 are electrically connected to the controller for transducing temperature of the magnesium melt 38 in the first chamber 26 into first temperature signals (not shown) and the temperature of the purified magnesium melt 40 in the second chamber 40 into second temperature signals (not shown).
- the first and second temperature signals are transmitted to the controller.
- the controller uses a control function (not shown) to determine and control the heat output of the heating apparatus, thereby maintaining the magnesium melt 38 and the purified magnesium melt 40 in a molten state and to prevent overheating thereof. In the molten state, the viscosities of both the magnesium melt 38 and the purified magnesium melt 40 are greatly reduced, thereby facilitating flow thereof through the filter 32 .
- the crucible 22 is preferably enclosed for receiving and retaining protective gas therein.
- a gas feed system (not shown) is connected to the crucible for supplying the protective gas thereinto.
- the protective gas prevents both the magnesium melt 38 and the purified magnesium melt 40 from reacting with the atmosphere by forming a screen therebetween.
- An extractor 44 extends from within the second chamber 28 to a die-casting assembly 46 .
- the extractor 44 is for extracting the purified magnesium melt 40 from the second chamber 28 and providing the purified magnesium melt 40 to the die-casting assembly 46 .
- the extractor 44 shown in FIG. 1 uses a piston and a goose-neck chamber assembly for extracting the purified magnesium melt 40 .
- Extracting the purified magnesium melt 40 from the second chamber 28 reduces the level of the purified magnesium melt 40 contained therein.
- the reduction of the level of the purified magnesium melt 40 in the second chamber 28 further draws the magnesium melt 38 from the first chamber 26 and into the second chamber 28 .
- Magnesium melt and magnesium ingots or scraps can be further provided to the first chamber 26 for replenishing the second chamber 28 and thereby the filtration system 20 with purified magnesium melt 40 .
- the purified magnesium melt 40 supplied from the filtration system 20 to the die-casting assembly 46 provides the die-casting assembly with a substantially inclusion-free purified magnesium melt 40 supply for use in a die-casting process.
- the alloy used in the tests was AZ91 HP having a composition of Al 8-9.5%, Zn 0.3-1.0%, Mn ⁇ 0.17%, Si ⁇ 0.05%, Fe ⁇ 0.004%, Cu ⁇ 0.015%, Ni ⁇ 0.01%, others ⁇ 0.01%, others ⁇ 0.01%, Mg (remaining).
- AZ91 HP having a composition of Al 8-9.5%, Zn 0.3-1.0%, Mn ⁇ 0.17%, Si ⁇ 0.05%, Fe ⁇ 0.004%, Cu ⁇ 0.015%, Ni ⁇ 0.01%, others ⁇ 0.01%, others ⁇ 0.01%, Mg (remaining).
- the tests were conducted using 100% fresh ingot and ingot including 10% scraps material.
- microstructure analysis was conducted with light optical microscopy (LOM) while mechanical properties were determined using an Instron tensile testing machine.
- LOM light optical microscopy
- the cross-head speed was varied from 0.1 to 20 mm/min during tensile tests.
- Typical microstructures for the tensile test specimen having a diameter of 10 mm-thick walled part and a mobile phone case, having a wall thickness of 0.6 mm-thin wall part.
- the microstructures consist mainly of ⁇ -Mg, intermetallic-Al 2 Mg 17 , eutectic composition and some fine precipitate.
- the thin walled parts showed much finer structure, as shown in FIGS. 7 a and 7 b , when compared to the thick walled parts shown in FIGS. 6 a and 6 b .
- the reduced ⁇ -Mg grain size is due to rapid solidification rate occurred in the thin walled part.
- FIGS. 8 a and 8 b show the tensile strength, comprising the ultimate tensile strength (ITS) and yield strength (YS) and elongation as a function of the cross-head speed.
- ITS ultimate tensile strength
- YS yield strength
- elongation as a function of the cross-head speed.
- the UTS and YS are about 142 and 119 MPa respectively with an elongation of about 1%.
Abstract
Magnesium alloys are heated to a molten state in preparation for hot-working thereof, for example, die-casting. The presence of inclusions within the magnesium alloys results in metallurgical defects therein and will adversely affect the quality of the castings produced from the magnesium alloys. An embodiment of the invention processes the magnesium melt containing impurities through a non-reactive filter under an environment filled with protective gas for substantially purifying the magnesium melt and to reduce the presence of inclusions in castings formed therefrom.
Description
- The present invention relates generally to a filtration system for purifying magnesium. Specifically, the present invention relates to a filtration system for recycling and purification of scrap magnesium and magnesium ingots with impurities.
- Magnesium alloys are heated to a molten state in preparation for hot-working thereof. Molten magnesium alloys easily oxidise and react with impurities, especially when scrap magnesium alloys are reused. As a result, magnesium alloys are contaminated by non-metallic and metallic inclusions, for example oxides or intermetallic compounds, when melted.
- The magnesium alloys are typically melted for producing castings. The presence of inclusions within the magnesium alloys results in metallurgical defects therein and will adversely affect the quality of the castings produced from the magnesium alloys.
- A known method for removing the impurities is to send the magnesium alloys to a smelter for smelting. However, smelting is a costly process. Another known process uses impediment plates disposed within a furnace for removing top and bottom sludge from magnesium melts. However, the impediment plates do not remove inclusions suspended in the magnesium melts.
- Hence, this clearly affirms a need for a filtration system for purifying magnesium melts.
- In accordance with a first aspect of the invention, there is disclosed a filtration system for magnesium recycling and purification, the filtration system comprising:
-
- a first chamber for containing magnesium melt, the magnesium melt containing impurities; and
- a second chamber for receiving purified magnesium melt,
- wherein said first and second chambers have disposed therebetween a filter, the filter being a silicon-free medium.
- In accordance with a second aspect of the invention, there is disclosed a filtration method for magnesium recycling and purification, comprising the steps of:
-
- receiving magnesium melt into a first chamber, the magnesium melt containing impurities within the first chamber containing impurities;
- providing a second chamber, the second chamber being in fluid communication with the first chamber; and
- substantially removing the impurities from the magnesium melt flowing from the first chamber into the second chamber using a filter, the filter being disposed between the first chamber and the second chamber and the filter including a silicon-free medium.
- In accordance to a third aspect of the invention, there is disclosed a filtration method for magnesium recycling and purification, comprising the steps of:
-
- receiving magnesium into a first chamber, the magnesium within the first chamber containing impurities and the magnesium being one of a magnesium melt or solid magnesium ingot;
- providing a second chamber, the second chamber being in fluid communication with the first chamber;
- heating the magnesium contained in the first chamber by a heating apparatus for melting the magnesium and for maintaining the magnesium melt in a molten state, and the magnesium melt in the first chamber thereby flowing into the second chamber; and
- substantially removing the impurities from the magnesium melt flowing from the first chamber into the second chamber using a filter, the filter being disposed between the first chamber and the second chamber and the filter including a silicon-free medium.
- Embodiments of the invention are described hereinafter with reference to the following drawings, in which:
-
FIG. 1 shows a partial front sectional view of a filtration system according to an embodiment of the invention; -
FIG. 2 shows a partial side sectional view of the filtration system ofFIG. 1 ; -
FIG. 3 is an illustration of a filter of the filtration system ofFIG. 1 ; -
FIG. 4 is an illustration of a first chamber and the filter ofFIG. 3 ; -
FIG. 5 a shows a low magnification light optical microscope (LOM) micrograph of a tensile specimen made from magnesium melt obtained from the filtration system ofFIG. 1 ; -
FIG. 5 b shows the LOM micrograph ofFIG. 5 a under high magnification; -
FIG. 6 a shows a low magnification light optical microscope (LOM) micrograph of a mobile phone case specimen made from magnesium melt obtained from the filtration system ofFIG. 1 ; -
FIG. 6 b shows the LOM micrograph ofFIG. 6 b under high magnification; -
FIG. 7 a shows a graph plotting the tensile strength (ultimate tensile strength and yield strength) of test samples as a function of cross-head speed with the test samples being cast from a magnesium melt purified using the filtration system ofFIG. 1 ; and -
FIG. 7 b shows a graph plotting the percentage elongation of the test samples ofFIG. 7 b, as a function of cross-head speed. - An embodiment of the invention, a
filtration system 20 is described with reference toFIG. 1 , which shows a partial front sectional view of thefiltration system 20 andFIG. 2 which shows a partial side sectional view of thefiltration system 20. Thefiltration system 20 is for use in substantially purifying magnesium. - As shown in
FIG. 1 , thefiltration system 20 includes acrucible 22 being divided into two parts by afilter adapter 24 disposed therein, the two parts of the crucible being namely afirst chamber 26 and asecond chamber 28. Thefirst chamber 26 is in fluid communication with thesecond chamber 28 through anopening 30, as shown inFIG. 2 , in thefilter adapter 24 that forms a passageway therebetween. - As shown in
FIG. 2 , thefilter adapter 24 is for receiving afilter 32 therewithin and for removably engaging thereto.FIG. 3 is an illustration of thefilter 32 andFIG. 4 is an illustration of thefirst chamber 26 and thefilter 32. When thefilter 32 is engaged to thefilter adapter 24, thefilter 32 blocks theopening 30 of thefilter adapter 24, thereby intersecting the passageway between thefirst chamber 26 and thesecond chamber 28, as shown inFIGS. 1, 2 and 5. Thefilter adapter 24 is preferably a steel structure that shaped and dimensioned for holding thefilter 32 at the periphery thereof. - The
filtration system 20 further includes a heating apparatus coupled to thecrucible 22. The heating apparatus is preferably integrated with thecrucible 22 for providing heat to thecrucible 22 and its contents. The heating apparatus is electrically connected to a controller (all not shown). - The
filtration system 20 is for providing substantially purified magnesium melts to downstream systems or machineries, for example, a die-casting machine. For obtaining purified magnesium melts from thefiltration system 20, magnesium ingots or scraps are provided to thefirst chamber 26 of thefiltration system 20. The controller activates the heating apparatus to provide heat to thecrucible 22 and the magnesium therein, thereby melting the magnesium. - Alternatively, magnesium melt can be provided to the
first chamber 26 of thecrucible 22. The heating apparatus provides heat to thecrucible 22 to maintain the magnesium melt in its molten state and to melt the magnesium scraps and ingots added to the magnesium melt thereafter. - The
filter 32 of thefiltration system 20 is preferably made of a silicon-free material. Conventional filters, for example a filter for aluminium alloys, are made of silicon-based materials. The silicon-based materials readily react with magnesium to cause contamination therein and are therefore undesirable. Thefilter 32 is made of one of steels or ceramic material which comprises of one or more material selected from a group consisting of Al2O3, MgO, AlPO4 and Mg3(PO4)2. - The
filter 32 comprises of an array of apertures (not shown). Each of the apertures is shaped and dimensioned for preventing the passage of a particle having a size greater than 5 microns therethrough. Preferably, each pair of adjacent apertures are spaced apart a distance of 5 to 250 microns. The magnesium melt 38 in thefirst chamber 26 passes through thefilter 32 and into thesecond chamber 28 of thecrucible 22. Therefore, the impurities suspended in themagnesium melt 38 contained in thefirst chamber 26 is substantially removed by thefilter 32 before entering thesecond chamber 28 as purifiedmagnesium melt 40. Themagnesium melt 38 contained in thefirst chamber 26 contains bottom sludge that has settled at the bottom of thefirst chamber 26. In most situations, top sludge can also be found floating at the surface of themagnesium melt 38 contained in thefirst chamber 26. Thefilter adapter 24 functions to substantially impede the top sludge and bottom sludge in thefirst chamber 26 from entering the second chamber 28 (all not shown). - With reference to
FIG. 1 , themagnesium melt 38 in thefirst chamber 26 is drawn into thesecond chamber 28 by hydrostatic forces acting on themagnesium melt 38. Themagnesium melt 38 in thefirst chamber 26 continues to be drawn into the second chamber until the hydrostatic pressures ofmagnesium melt 38 in thefirst chamber 26 and the purifiedmagnesium melt 40 in thesecond chamber 28 are in equilibrium. - Preferably, each of the
first chamber 26 and thesecond chamber 28 has athermocouple 42 disposed therewithin. Both thethermocouples 42 are electrically connected to the controller for transducing temperature of themagnesium melt 38 in thefirst chamber 26 into first temperature signals (not shown) and the temperature of the purifiedmagnesium melt 40 in thesecond chamber 40 into second temperature signals (not shown). The first and second temperature signals are transmitted to the controller. From the first and second temperature signals, the controller uses a control function (not shown) to determine and control the heat output of the heating apparatus, thereby maintaining themagnesium melt 38 and the purifiedmagnesium melt 40 in a molten state and to prevent overheating thereof. In the molten state, the viscosities of both themagnesium melt 38 and the purifiedmagnesium melt 40 are greatly reduced, thereby facilitating flow thereof through thefilter 32. - The
crucible 22 is preferably enclosed for receiving and retaining protective gas therein. A gas feed system (not shown) is connected to the crucible for supplying the protective gas thereinto. The protective gas prevents both themagnesium melt 38 and the purifiedmagnesium melt 40 from reacting with the atmosphere by forming a screen therebetween. - An
extractor 44, as shown inFIG. 1 , extends from within thesecond chamber 28 to a die-castingassembly 46. Theextractor 44 is for extracting the purifiedmagnesium melt 40 from thesecond chamber 28 and providing the purifiedmagnesium melt 40 to the die-castingassembly 46. Theextractor 44 shown inFIG. 1 uses a piston and a goose-neck chamber assembly for extracting the purifiedmagnesium melt 40. - Extracting the purified
magnesium melt 40 from thesecond chamber 28 reduces the level of the purifiedmagnesium melt 40 contained therein. The reduction of the level of the purifiedmagnesium melt 40 in thesecond chamber 28 further draws themagnesium melt 38 from thefirst chamber 26 and into thesecond chamber 28. Magnesium melt and magnesium ingots or scraps can be further provided to thefirst chamber 26 for replenishing thesecond chamber 28 and thereby thefiltration system 20 with purifiedmagnesium melt 40. - The purified
magnesium melt 40 supplied from thefiltration system 20 to the die-castingassembly 46 provides the die-casting assembly with a substantially inclusion-freepurified magnesium melt 40 supply for use in a die-casting process. - Two types of parts, hand-phone case and tensile test specimens, were cast during tests. The alloy used in the tests was AZ91 HP having a composition of Al 8-9.5%, Zn 0.3-1.0%, Mn≧0.17%, Si≦0.05%, Fe≦0.004%, Cu≦0.015%, Ni≦0.01%, others ≦0.01%, others ≦0.01%, Mg (remaining). For comparison the tests were conducted using 100% fresh ingot and ingot including 10% scraps material.
- After casting, the microstructure and chemical properties of the specimens were analyzed. The microstructure analysis was conducted with light optical microscopy (LOM) while mechanical properties were determined using an Instron tensile testing machine. The cross-head speed was varied from 0.1 to 20 mm/min during tensile tests.
- Typical microstructures for the tensile test specimen, having a diameter of 10 mm-thick walled part and a mobile phone case, having a wall thickness of 0.6 mm-thin wall part. In both thick and thin walled parts, the microstructures consist mainly of α-Mg, intermetallic-Al2Mg17, eutectic composition and some fine precipitate. However, the thin walled parts showed much finer structure, as shown in
FIGS. 7 a and 7 b, when compared to the thick walled parts shown inFIGS. 6 a and 6 b. The reduced α-Mg grain size is due to rapid solidification rate occurred in the thin walled part. - Mechanical properties of cast samples were determined after casting.
FIGS. 8 a and 8 b show the tensile strength, comprising the ultimate tensile strength (ITS) and yield strength (YS) and elongation as a function of the cross-head speed. As the cross-head speed is directly related to the strain rate of the testing, the results obtained indicated that the strain rate has a very slight influence on the flow stress and strain of magnesium castings when tested at room temperature. The UTS and YS are about 142 and 119 MPa respectively with an elongation of about 1%. - A comparison was made between the mechanical properties of castings made with filtered magnesium (with about 10% scraps) and castings made with fresh magnesium (100% new ingot). The strength of the castings is increased when filtered magnesium is used as compared to when 100% new magnesium ingot is used. However, the ductility of the magnesium alloys is reduced. The decreased ductility is typically due to the presence of more intermetallic compounds and less magnesium in the alloy having scrap parts therein although the alloy has already been filtered. Therefore, the composition of the alloy should be adjusted when using scrap parts.
- In the foregoing manner, a filtration system is described according to an embodiment of the invention for addressing the foregoing disadvantages of conventional filtration devices. Although only one embodiment of the invention is disclosed, it will be apparent to one skilled in the art in view of this disclosure that numerous changes and/or modification can be made without departing from the scope and spirit of the invention.
Claims (20)
1. A filtration system for magnesium recycling and purification, the filtration system comprising:
a fast chamber for containing magnesium melt the magnesium melt containing impurities ad the first chamber enclosing the magnesium melt containing impurities therein; and
a second chamber for receiving purified magnesia melt, the second chamber enclosing the purified magnesium melt therein and the first and second chambers respectively separating the magnesium melt containing impurities and the purified magnesium melt from the atmosphere,
wherein sad first and second chambers have disposed therebetween a filter, the filter being a silicon-free medium, and each of the first chamber and the second chamber for further containing and enclosing protective gases therein.
2. The filtration system as in claim 1 , the second chamber being in fluid communication with the first chamber and the filter for substantially removing the impurities from the magnesium melt flowing from the first chamber into the second chamber.
3. The filtration system as in claim 1 , further comprising;
a heating apparatus integrated with the first and second chambers for maintaining the magnesium melt contained in the first and second chambers in a molten state.
4. The filtration system as in claim 1 , further comprising.
a filter adapter disposed between the first chamber and the second chamber, the filter being removably coupled to the filter adapter and the filter adapter for positioning the filter to interface the first chamber and the second chamber.
5. The filtration system as in claim 1 , the filter comprising one of steel or ceramic material.
6. The filtration system as in claim 5 , the filter further comprises at least one material selected from a group consisting of Al2O3, MgO, AlPO4 and Mg3(PO4)2.
7. The filtration system as m claim 1 , the filter comprising an array of at least one aperture.
8. The filtration system as in claim 7 , each of the at least one aperture being shaped and dimension for preventing passage of a panicle having a size greater than 5 microns therethrough.
9. The filtration system as in claim 7 , each pair adjacent apertures being spaced apart a distance of 5 to 250 microns.
10. The filtration system as in claim 1 , further comprising a temperature control system for regulating temperature of the magnesium melt within the first chamber and the second chamber.
11. The filtration system as in claim 10 , the temperature control system, comprising:
a controller, the heating apparatus being electrically connected to the controller;
a first thermocouple being electrically connected to the controller and being disposed within the first chamber for transducing temperature of the magnesium melt therein into first temperature signals; and
a second thermocouple being electrically connected to the controller and being disposed within the second chamber for transducing temperature of the filtered magnesium melt therein into second temperature signals,
wherein the first temperature signals and the second temperature signals are transmitted to the controller, the controller having a control function for controlling the heating apparatus and thereby maintaining the magnesium melt in a molten state and preventing overheating of the magnesium melt.
12. The filtration system as in claim 1 , further comprising a gas feed system for introducing a protective gas in to the first and second chambers.
13. The filtration system as in claim 1 , further comprising a step of:
an extractor for extracting the magnesium melt from the second chamber, the extractor being extending from within the second chamber to a die-casting assembly, the extractor for providing the extracted magnesium melt to the die-casting assembly.
14. A filtration method for magnesium recycling and purification, comprising the steps of:
receiving magnesium melt into a first chamber, the magnesium melt containing impurities within the first chamber containing impurities and the first chamber enclosing the magnesium melt containing impurities therein;
providing a second chamber, the second chamber being in fluid communication with the first chamber, the second chamber enclosing the purified magnesium melt herein and the first and second chambers respectively separating the magnesium melt containing impurities and the purified magnesium melt from the atmosphere; and
substantially removing the impurities from the magnesium melt flowing from the first chamber into the second chamber using a filter, the filter being disposed between the first chamber and the second chamber, each of the first chamber and the second chamber for further containing and enclosing protective gases therein, and the filter including a silicon-free medium.
15. The filtration method as in claim 14 , ether comprising a step of:
providing a heating apparatus integrated with the first and second chambers for maintaining the magnesium melt contained in the first and second chambers in a molten state.
16. The filtration method as in claim 14 , the filter comprising one of steel or ceramic material.
17. The filtration method as in claim 15 , further comprising a step of providing a temperature control system for regulation temperature of the magnesium melt within the first chamber and the second chamber.
18. The filtration method as in claim 17 , the temperature control system comprising:
a controller, the heating apparatus being electrically connected to the controller;
a first thermocouple being electrically connected to the controller and being disposed within the first chamber for transducing temperature of the magnesium melt therein into first temperature signals; and
a second thermocouple being electrically connected to the controller and being disposed within the second chamber for transducing temperature of the filtered magnesium melt therein into second temperature signals,
wherein the first temperature signals and the second temperature signals are transmitted to the controller, the controller having a control fraction for controlling the heating apparatus and thereby maintaining the magnesium melt in a molten state and preventing overheating of the magnesium melt.
19. The filtration method as in claim 14 , further comprising a step of:
extracting the magnesium melt from the second chamber by an extractor, the extractor extending from within the second chamber to a die-casting assembly, the extractor for providing the extracted magnesium melt to the die-casting assembly.
20. A filtration method for magnesium recycling and purification, comprising the steps of:
receiving magnesium into a first chamber, the magnesium within the first chamber containing impurities, the first chamber enclosing the magnesium melt containing impurities therein and the magnesium being one of a magnesium melt or solid magnesium ingot;
providing a second chamber, the second chamber being in fluid communication with the first chamber, the second chamber enclosing the purified magnesium melt therein and the fist and second chambers respectively separating the magnesium melt containing impurities and the purified magnesium melt from the atmosphere;
heating the magnesium contained in the fist chamber by a heating apparatus for melting the magnesium and for maintaining the magnesium melt in a molten state, and the magnesium melt in the first chamber thereby flowing into the second chamber; and
substantially removing the impurities from the magnesium melt flowing from the first chamber into the second chamber using a filter, the filter being disposed between the first chamber and the second chamber, each of the first chamber and the second chamber for further containing and enclosing protective gases therein, and the filter including a silicon-free medium.
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
SG200106275A SG121696A1 (en) | 2001-10-19 | 2001-10-19 | Filtration system for recycling and purification of a magnesium melt |
SGSG200106275-1 | 2001-10-19 | ||
PCT/SG2002/000238 WO2003033748A1 (en) | 2001-10-19 | 2002-10-18 | A filtration system for magnesium recycling and purification |
Publications (1)
Publication Number | Publication Date |
---|---|
US20050029718A1 true US20050029718A1 (en) | 2005-02-10 |
Family
ID=20430845
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US10/493,006 Abandoned US20050029718A1 (en) | 2001-10-19 | 2002-10-18 | Filtration system for magnesium recycling and purification |
Country Status (3)
Country | Link |
---|---|
US (1) | US20050029718A1 (en) |
SG (1) | SG121696A1 (en) |
WO (1) | WO2003033748A1 (en) |
Cited By (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
KR101039725B1 (en) | 2009-03-23 | 2011-06-09 | (주)이노캐스트 | Apparatus and method for regenerating scrap of magnesium alloy |
WO2016131174A1 (en) * | 2015-02-16 | 2016-08-25 | 谭何易 | Production line for producing national-standard magnesium alloy ingots on the basis of magnesium alloy waste material |
CN108193061A (en) * | 2017-12-21 | 2018-06-22 | 李本根 | A kind of purifying plant for rare earth feed liquid |
CN108237206A (en) * | 2018-02-28 | 2018-07-03 | 厦门格欧博新材料科技有限公司 | A kind of salt core former |
CN110724833A (en) * | 2019-11-27 | 2020-01-24 | 国科镁业科技(河南)有限公司 | Application of simple substance silicon filter material in gas-phase magnesium purification and production system comprising same |
CN113444888A (en) * | 2021-06-29 | 2021-09-28 | 重庆大学 | Method for purifying magnesium melt by adopting directional solidification |
Families Citing this family (2)
Publication number | Priority date | Publication date | Assignee | Title |
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AU2005215071B2 (en) * | 2004-02-24 | 2010-02-11 | Alcan International Limited | Method of priming filter for molten metal |
CN108311652B (en) * | 2018-02-06 | 2019-12-17 | 洛阳晟雅镁合金科技有限公司 | Preparation process of ME20M magnesium alloy slab ingot |
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Cited By (6)
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KR101039725B1 (en) | 2009-03-23 | 2011-06-09 | (주)이노캐스트 | Apparatus and method for regenerating scrap of magnesium alloy |
WO2016131174A1 (en) * | 2015-02-16 | 2016-08-25 | 谭何易 | Production line for producing national-standard magnesium alloy ingots on the basis of magnesium alloy waste material |
CN108193061A (en) * | 2017-12-21 | 2018-06-22 | 李本根 | A kind of purifying plant for rare earth feed liquid |
CN108237206A (en) * | 2018-02-28 | 2018-07-03 | 厦门格欧博新材料科技有限公司 | A kind of salt core former |
CN110724833A (en) * | 2019-11-27 | 2020-01-24 | 国科镁业科技(河南)有限公司 | Application of simple substance silicon filter material in gas-phase magnesium purification and production system comprising same |
CN113444888A (en) * | 2021-06-29 | 2021-09-28 | 重庆大学 | Method for purifying magnesium melt by adopting directional solidification |
Also Published As
Publication number | Publication date |
---|---|
SG121696A1 (en) | 2006-05-26 |
WO2003033748A1 (en) | 2003-04-24 |
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