WO2023038591A1 - Flux composition for copper-based alloys - Google Patents
Flux composition for copper-based alloys Download PDFInfo
- Publication number
- WO2023038591A1 WO2023038591A1 PCT/TR2021/050961 TR2021050961W WO2023038591A1 WO 2023038591 A1 WO2023038591 A1 WO 2023038591A1 TR 2021050961 W TR2021050961 W TR 2021050961W WO 2023038591 A1 WO2023038591 A1 WO 2023038591A1
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- WO
- WIPO (PCT)
- Prior art keywords
- copper
- sodium
- fluoride
- based alloys
- flux composition
- Prior art date
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Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
- B23K35/22—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
- B23K35/36—Selection of non-metallic compositions, e.g. coatings, fluxes; Selection of soldering or welding materials, conjoint with selection of non-metallic compositions, both selections being of interest
- B23K35/362—Selection of compositions of fluxes
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
- B23K35/22—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
- B23K35/36—Selection of non-metallic compositions, e.g. coatings, fluxes; Selection of soldering or welding materials, conjoint with selection of non-metallic compositions, both selections being of interest
- B23K35/3601—Selection of non-metallic compositions, e.g. coatings, fluxes; Selection of soldering or welding materials, conjoint with selection of non-metallic compositions, both selections being of interest with inorganic compounds as principal constituents
- B23K35/3603—Halide salts
- B23K35/3605—Fluorides
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
- B23K35/22—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
- B23K35/36—Selection of non-metallic compositions, e.g. coatings, fluxes; Selection of soldering or welding materials, conjoint with selection of non-metallic compositions, both selections being of interest
- B23K35/3612—Selection of non-metallic compositions, e.g. coatings, fluxes; Selection of soldering or welding materials, conjoint with selection of non-metallic compositions, both selections being of interest with organic compounds as principal constituents
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C9/00—Alloys based on copper
-
- 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
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Materials Engineering (AREA)
- Metallurgy (AREA)
- Organic Chemistry (AREA)
- Inorganic Chemistry (AREA)
- Manufacture And Refinement Of Metals (AREA)
- Continuous Casting (AREA)
- Curing Cements, Concrete, And Artificial Stone (AREA)
Abstract
The invention relates to a flux composition developed for increasing the casting quality of the copper-based alloys, comprising potassium aluminum fluoride (KAIF4), calcium fluoride (CaF2), sodium fluoride (NaF), borax pentahydrate (Na2B407.5 H20), fine pearlite, sodium carbonate (Na2C03), sodium chloride (NaCI), potassium chloride (KCI) and graphite (C), and its production method thereof.
Description
FLUX COMPOSITION FOR COPPER-BASED ALLOYS
Technical Field
The invention relates to flux used in the non-ferrous industry, copper and copper alloys industry, and casting of copper-based alloys.
The invention particularly relates to the flux composition and production method developed to improve the melting process of copper-based alloys and to increase the quality of the melted liquid and casting.
The Known State of the Art
Fluxes are casting chemicals in the form of powder, granules, etc., and are used to remove the oxidized compounds, impurities, and unwanted elements in the liquid metal from the liquid metal bath, to turn the metal into a clean melt suitable for casting, and also to provide degassing by cutting off the contact with the atmosphere. Fluxes are applied by covering the liquid metal inside the pot. Different types of fluxes are available for cleaning, covering, impurity removal, inclusion, and slag removal.
Today, foundries are using more fluxing processes to ensure the chemical, physical and mechanical properties of metals. Many types of fluxes are commercially available in the market with the aim of reducing the melting and casting expenses of the enterprises and increasing the casting quality thereof. Fluxes mainly contain either carbon-based charcoal, graphite, lampblack, or sodium and potassium chloride salts and minor fluoride salts. These types of fluxes are added to the melting furnaces and form an inert atmosphere over the liquid, protect the furnace refractor, prevent oxidation, prevents heat losses on the molten liquid surface, flocculates impurities and cleans slag (agglomerates), and acts as a protective element during the melting of thin materials.
During the melting process, the liquid metal tends to oxidize due to the high affinity of elements such as beryllium, zirconium, phosphorus, iron, zinc, silicon, aluminum, manganese in copper-based alloys that come into contact with oxygen in the atmosphere. If these oxides are present during melt product solidification,
they segregate along the grain boundaries and deteriorate the mechanical properties. During casting, refractory materials, scrap, return materials such as sawdust after processing and waste materials from the previous casting enter into the molten metal. All these materials and the environment lead to the contamination of the liquid metal. This causes fusion and casting failures such as hydrogen, carbon and oxygen-based gas void, porosity, inclusion, impurity in the materials after casting.
Fluxes used for copper-based materials in the current technique accelerate the melting of metals with high melting point such as iron, manganese, chromium, nickel in the liquid metal and provide slag (impurities accumulated on the surface) cleaning processes in the liquid metal. However, it has been observed that the currently used fluxes have low performance in acting as a cover on the liquid metal that cuts off the contact with the air during the application process. This also increases the cost of the fluxes. The costs of casting processes also increase with high added value.
As a result, due to the above-mentioned disadvantages and inadequacy of the current solutions to meet the above-mentioned needs, it was necessary to make a development in the relevant technical field.
The Object of the Invention
The present invention relates to a flux composition for copper-based alloys meeting the above-mentioned needs, eliminating all disadvantages along with some additional advantages, and the production method thereof.
Primary object of the invention is to provide a flux composition developed to increase the casting quality of copper-based alloys thanks to the chemical ingredients in the flux composition.
An object of the invention is to provide a slag removal feature due to the chemicals in its content compared to the fluxes in the current technique, as well as to provide a cover on the liquid metal in the pot and to cut the connection of the liquid metal with the air.
Another object of the invention is to accelerate the melting process of metals by feeding the liquid metal together with metals with high melting point.
Another object of the invention is to prevent impurities from entering into the liquid metal with their apparent feature of cleaning the slag accumulated in the linings of induction furnaces over time.
Another object of the invention is to provide a flux that provides a cost advantage compared to its relevant competitors by reducing the flux costs due to its improved composition.
In order to achieve the above-mentioned objectives and provide the relevant features, the invention is a flux composition developed for improving casting quality for use in casting copper-based alloys, wherein it contains borax pentahydrate, fine perlite, sodium carbonate, sodium chloride, potassium chloride and graphite.
According to an application of the invention, flux composition for copper-based alloys contains 30-60% potassium aluminum fluoride, 10-35% calcium fluoride, 10- 25% sodium fluoride, 2-10% borax pentahydrate, 1 -5% fine pearlite, 1 -5% sodium carbonate, 1 -10% sodium chloride, 1 -10% potassium chloride and 0.5-3% graphite by weight of the total content.
In order to achieve the above-mentioned objectives, the invention is the production method of the flux composition for copper-based alloys, characterized by comprising the following process steps; i. Preparation of chemicals for the mixture, ii. Adding potassium aluminum fluoride, calcium fluoride, sodium fluoride, borax pentahydrate, fine perlite, sodium carbonate, sodium chloride and potassium chloride to the powder mixer machine and mixing the mixture until homogeneous, iii. Adding graphite to the mixture prepared in step (ii), iv. Mixing the mixture until homogeneous
The structural and characteristic features of the invention and all its advantages will be understood more clearly thanks to the figure given below and the detailed description, and the evaluation should be made taking into account this detailed description.
Detailed Description of the Invention
In this detailed description, the flux composition and production method and preferred embodiments for copper-based alloys according to the invention are merely explained for a better understanding of the subject of the invention, which is not intended to be limiting in any way.
The invention relates to the flux composition developed to improve the casting quality of copper-based alloys and the production method thereof.
The flux composition for the copper-based alloys according to the invention contains potassium aluminum fluoride (KAIF4), calcium fluoride (CaF2), sodium fluoride (NaF), borax pentahydrate (Na2B4O7.5 H2O), fine perlite, sodium carbonate (Na2CO3), sodium chloride (NaCI), potassium chloride (KCI) and graphite (C) in their most basic form.
Performance properties of the relevant flux have been improved compared to the fluxes currently used due to the fine perlite, graphite, borax pentahydrate, sodium carbonate, sodium chloride and potassium chloride in the flux composition according to the invention. Apart from its slag cleaning feature, flux according to the invention also acts as a cover on the liquid metal in the pot and cuts off the connection between the liquid metal and the air. The flux also accelerates the melting process of metals by feeding the liquid metal together with metals with high melting point. The flux also prevents impurities from entering into the liquid metal with their apparent feature of cleaning the slag accumulated in the linings of induction furnaces over time.
Table 1 sets forth the flux composition components and the approximate proportions of these components for the copper-based alloys according to the invention.
Table 1 : The components of the flux composition and the proportions of the overall content
Potassium aluminum fluoride is an exothermic reaction powder, but it also has a slag removal feature.
Calcium fluoride provides fluidity to the slag and saves energy as it quickly conducts heat transfer. It facilitates the impurities to pass to the slag. Furthermore, it also facilitates melting and ensures that undesired substances remain in the slag by being added to iron.
When sodium fluoride is added to the molten metal, it helps deoxidation or degassing of the molten metal, and is also used in the melting of light metals. Borax pentahydrate is used as a protective slag cleaner and melting accelerator in the non-ferrous metal industry, thanks to its ability to form a smooth, sticky, protective, clean and burr-free liquid at high temperatures.
Fine perlite prevents surface tensions by providing balanced cooling of the metal.
It provides a clean casting by collecting the scattered slag formed on the surface without reacting with the liquid metal.
Sodium carbonate (mild soda) is a solvent for silica and other oxides with its low reactivity and low melting temperature. It provides melting of all components at low temperature.
Sodium chloride imparts fluidity to the liquid metal. It helps to dissolve the remnant slag on the pot wall. It forms a thin layer on the liquid and helps to cut its contact with the air.
Potassium chloride imparts fluidity to the liquid metal. It helps to dissolve the remnant slag on the pot wall. It forms a thin layer on the liquid and helps to cut its contact with the air.
Graphite acts as a cover by being imputed over the liquid metal to cut off contact with the atmosphere.
The flux composition according to the invention mainly comprises the following process steps; i. Preparation of chemicals for the mixture, ii. Adding potassium aluminum fluoride, calcium fluoride, sodium fluoride, borax pentahydrate, fine perlite, sodium carbonate, sodium chloride and potassium chloride to the powder mixer machine and mixing the mixture until homogeneous, iii. Adding graphite to the mixture prepared in step (ii), iv. Mixing the mixture until homogeneous.
The chemicals are generally prepared at room temperature for the preparation of the powder mixture, and then, all chemicals (regardless of the addition order) are added to the powder mixer machine and mixed for 1 -5 minutes (in the process step ii) until a homogeneous mixture is obtained. Finally, graphite is added and the mixture is mixed for another 1 -2 minutes (in the iv process step) and the prepared homogeneous mixture is made ready for use and filled into plastic containers for storage.
The mixing time of the powder materials in the mixer machine should be between 1 and 5 minutes. Grain sizes of the powder particles will be smaller with the extended time, which is undesirable. As the flux powder size decreases, the
driving force for agglomeration will be greater, so it cannot provide a good covering on the liquid metal surface. The powder size of the flux according to the invention is between the range of 100-200 pm.
Graphite should be added to the powder mixture last. Graphite changes the color of the flux, and the mixture quickly provides a homogeneous appearance due to the color of it if being put at the beginning of the process. This may be misleading for a proper mixture.
By using an oxygen and hydrogen analyzer, the oxygen and hydrogen proportion in the liquid metal has been measured during casting. The proportion of the oxygen level has been between 250-1000 ppm, and the proportion of hydrogen has been between 15-40 ppm during the castings made by using commercial fluxes. The oxygen proportion has been between 10-50 ppm, and the hydrogen proportion has been between 1 -5 ppm during the castings made using the flux composition according to the invention.
The flux preparation process is an exothermic reaction and heat is released during this process, therefore, the person performing the application should take precautions against the heat in terms of work safety. The flux composition according to the invention is used in the non-ferrous industry, copper and copper alloys industry, and in the casting of copper-based alloys. Table 2 demonstrates the copper and copper alloys which may possibly benefit from flux composition according to the invention with UNS codes.
Table 2. Alloys that may benefit from flux composition
Claims
CLAIMS . A flux composition developed for improving casting quality for use in casting copper-based alloys, characterized by comprising borax pentahydrate, fine perlite, sodium carbonate, sodium chloride, potassium chloride and graphite. . The flux composition for copper-based alloys according to Claim 1 or 2, characterized by comprising 30-60% potassium aluminum fluoride, 10-35% calcium fluoride, 10-25% sodium fluoride, 2-10% borax pentahydrate, 1 -5% fine pearlite, 1 -5% sodium carbonate, 1 -10% sodium chloride, 1 -10% potassium chloride and 0.5-3% graphite by weight of the total content. . The flux composition for copper-based alloys according to Claim 1 or 2, characterized by comprising 30% potassium aluminum fluoride, 25% calcium fluoride, 25% sodium fluoride, 2% borax pentahydrate, 3% fine perlite, 5% sodium carbonate, 5% sodium chloride, 3% potassium chloride and 2% graphite by weight. . The production method of the flux component for copper-based alloys, characterized by comprising the following process steps; i. Preparation of chemicals for the mixture, ii. Adding potassium aluminum fluoride, calcium fluoride, sodium fluoride, borax pentahydrate, fine perlite, sodium carbonate, sodium chloride and potassium chloride to the powder mixer machine and mixing the mixture until homogeneous, iii. Adding graphite to the mixture prepared in step (ii), iv. Mixing the mixture until homogeneous . The production method of the flux composition for copper-based alloys according to Claim 5, characterized in that; (ii) the powder mixture is mixed for 1 -5 minutes during the production phase.
9
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| TR2021/014303A TR2021014303A2 (en) | 2021-09-13 | 2021-09-13 | Flux Composition for Copper Based Alloys |
| TR2021/014303 | 2021-09-13 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| WO2023038591A1 true WO2023038591A1 (en) | 2023-03-16 |
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ID=83999826
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| PCT/TR2021/050961 WO2023038591A1 (en) | 2021-09-13 | 2021-09-20 | Flux composition for copper-based alloys |
Country Status (2)
| Country | Link |
|---|---|
| TR (1) | TR2021014303A2 (en) |
| WO (1) | WO2023038591A1 (en) |
Citations (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US2195433A (en) * | 1938-02-03 | 1940-04-02 | American Brass Co | Process for producing boron-copper alloys |
| US4038068A (en) * | 1976-02-19 | 1977-07-26 | Olin Corporation | Method of melting copper alloys with a flux |
| CN107552748A (en) * | 2017-08-16 | 2018-01-09 | 徐高杰 | A kind of covering agent for smelting copper alloy and its application method |
-
2021
- 2021-09-13 TR TR2021/014303A patent/TR2021014303A2/en unknown
- 2021-09-20 WO PCT/TR2021/050961 patent/WO2023038591A1/en unknown
Patent Citations (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US2195433A (en) * | 1938-02-03 | 1940-04-02 | American Brass Co | Process for producing boron-copper alloys |
| US4038068A (en) * | 1976-02-19 | 1977-07-26 | Olin Corporation | Method of melting copper alloys with a flux |
| CN107552748A (en) * | 2017-08-16 | 2018-01-09 | 徐高杰 | A kind of covering agent for smelting copper alloy and its application method |
Also Published As
| Publication number | Publication date |
|---|---|
| TR2021014303A2 (en) | 2021-10-21 |
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