Theoretical training {rom 3" June till 9" June at TAFIME SA de CV; Created by: Date: TRAINING DOCUMENT “THE MELT SHOP” (Basic functions, Equipments, Quality and melt treatment) ueretaro; Mexico Andreas Kaleja ‘Supported by: AKG ENGINEERING MEXICO SA de CV Col, Bosques del Sol Bosques de Oyamel 139 B 4 QRO, 76113 Queretaro IG Frauahofer, Inet Bia June 2009 We eserenecnn trdatoterenaChapter A Chapter B Chapter C Chapter D NM Synopsis The melt-shop page3 - 5 Melt furnaces for non ferrous metals page 6-32 4 Classification of melt furnaces 1.1 Scope of the Melt shop of a non ferrous foundry 1.2 Classification by use 1.3 Classification by Energy supply 1-4 Classification by type of construction 2 Energy for melting and holding 2.1 Primary enorgy’s 2.2 Secondary eneray’s 3 Furnaces 8.1 general requirements 3.2 Combustible heated melt & holding furnaces 8.8 Electric heated met & holding furnaces 4 Liquid metal supply Melting process from non-ferrous alloys page 33-46 4 Problem of non-ferrous motel smelting 2 Melting technique of aluminum alloys 2.1 Feedstack’s 2.2 Fundamentals of Melt Treaiment 23 Melt Treatment Funds 24 Dogassing method's for aluminum alloys 2.5 Method's of cleaning 2.6 Pellet refining 2.7 Melling process and treatment monitoring The high pressure Die casting product page 47 - 49 Talime-Traning-Meltshop-Engr-compldoe ae "AKG ENGINEERING HEXICO SA DE Gv "Andoas Kea; 7/272000MATa Chapter A The melt-shop 1.1) Tasks of a melting operation: €) The liquid metal must be provided with the chemical composition and metallurgical state of the foundry. The chemical composition is a prerequisite for obtaining the proporties in the casting 'b) The melt has a high degree of uniformity, in the context of a modem production, quality is more important to secure compliance with the material requirements than the rare achievement of peak properties. ©) The liquid metal must be provided at the right time, in sufficient quantity, in the specified quality, reproducible and with a defined melting temperature. 4) Tho melt-shop must be in spite of all the optimization sufticient flexibility in the use of substances, quantities, performance, both short-term changes such as long-term. With this the cost of operating outside the optimum should not increase dramatically 1,2) Individual functions of the melting operation The objectives of the melt-shop, in conjunction with the other departmenis of the foundry business, show the following specific functions: = About the multiple material flows is the smelter combined with the other departments, ‘These linkages should be explained exemplary for a smelter (see paragraph 2), - In the storage area are the insert materials for the smelter to store. In this connection, the quality of each lot is carefully to capture and the different varieties must be arranged that way that the needed amount, regarding to the mixture order, can be provided to the melting operation. - Aluminum alloys ate mainly melted in shaft and chamber fumaces and will also be saved for the casting operation. For the accurate adjustment of the aluminum varieties, according to the standards, melt treatment and quality assurance checks has to be done in the furnace. “Taina Talning Melishop-Eng- compl dos 3148 "AKG ENGINEERING MEXICO SADE GV "Andas Kaloja; 7/2/2009C AIR Internal Material flow To get a frst overview of the work in the smelter and its linkage with the overall foundry, the material flow is observed. 1 (sex | [a | ‘The Material flow in a melt shop. ‘The following materials will be provided from the stock, in a precise provision to the smelter, where: Aluminum Ingots, as they are produced in the smelting of aluminum and will be used as alloy substrate with a controlled composition witch is needed for the casting operation, Aluminum scraps as a cheap commodity, which must be enriched in the melt with silicon, magnesium and other agaregates to get a base alloy. Casting breaks already has a similar composition as the desired melt, Casting break consists of older castings, after the end of their use they will be re-melted, Pre-Alloy's have particularly high levels of certain elements which are important for the aluminum, such as silicon makers, makers of manganese, phosphorus cattor. Jn the meit-shop will be also brought in: circuit material such as runners, scrap and gages from the casting operations. The composition corresponds nearly to the new mell. The percentage varies depending on the cast and casting part geometries. It is 30 up tl 80% of the total amount. ae "AKG ENGINEERING MEXICO SA DE CV "Andreas Kalla; 7/2/20097 INGA In the mett-shop will be exercised following three main functions: + Melting + Saving / Storage + Melt treatment Depending on the needed alloy composition and according to the operational requirements, the foundry will get the molten metal after cleaning out of a holding furnace. The Casted part arrives in the processing. From there, the loop material is fed back to the melting operation and the good casting will go on the shipment to the customer. Talim Tang Meltshop-Eng-compldoe 3149 "AKG ENGINEERING MEXICO SA DE GV ‘Anciees Kaleja 71272008,NTA Chapter B Melt furnaces for non ferrous metals 1 Classification of melt furnaces 4.4 Scope ofthe Melt shop of a non ferrous foundry 4.2 Classication by use 1.3 Classlcation by Enorgy supply 1:4 Classilcation by typo of construction 2 Energy for melting and holding 2.1 Primary enoray’s 2.2 Secondary enargy's 3 Furnaces. 8.4 genoral requirements 3.2 Combustible heated molt & holding lumaces 3.3 Eloctic heated melt & holding furnaces 4 Liquia metal supply 1. Classification of melt furnaces 1.1 Scope of the Melt shop of anon ferrous foundry Goal of all production activities in a foundry and also of the Melt shop is the production of saleable castings, at such prices, which at feast cover the cost and the operation beyond a long- term existence. All actions in the Melt shop are driven of this final goal and must be given. To the customer is to deliver a casting with specified properties (generally standardized) in special the material properties: ‘+ The Material properties will be given through the material microstructure which in the few seconds or minutes (between filing alter pouring and the end of crystallization) arises. ‘+ The material microstructure is specified by the composition of the melt, through its treatment before casting and by the cooling circumstances during the crystallization. + The Melt treatment has to take into account, such as the composition of the melt (burning, introduced elements), oxidation products and dissolved gases. Tallme-Treling-Meltshop-Eng-complidoo 6148 "AKG ENGINEERING MEXICO SA DE GV ‘Andreas Kalela; 71272008,AT 1.2 Classification by use In order of this complex task in the melt shop of a nonferrous metal founcty, the installed ovens have different tasks. The furnaces can be used optimized in each form for specific operations or for a multi-functional use. By the type of use It willbe distinguish: ‘+ Melt furnaces, for which relatively much energy por unit volume is supplied to the heating and melting of the metal, are used for a short melt period. ‘+ Holding furnaces, which often have a large capacity to align the melt. A relatively low ‘energy intake is designed, because only temperature losses should be compensated. ‘+ Casting furnaces are filed with the pre-melt, and then they dosing the exact amount of metal into the mold or chamber ‘© Special furnaces meet e.g. as Melt & Holding furnaces multiple tasks, 1.3 Classification by energy supply Another classification of furnaces in the melting operation of a foundry selects the type of heat from the injected energy to the distinguishing feature: + To the furnaces with primary energy supply from fossil fuels include those that are natural gas, {uel oil or coke (only rarely encountered, because it is not easy to handle) use. These ovens heated with fuel were widespread, For operational, organizational, metallurgical, economic and environmental reasons, they are increasingly replaced by electric. + In the electric non-terrous metal foundries, the electrical energy supplied by resistance elements (eg heating spiral, resistance rods) or by induction coils for heating. 1.4 Classification by type of Construction Third classifications are the structural features and disposition of the furnaces. The organization of space, which takes the liquid metal give the names: * Crucible furnace + Bath- or Stove furnace + Shaft furnaco © Drum furnace ‘The principia of the classifications can also be used combined, for example, if in a holding furnace electricity is used to heat the metal which is in a commercial crucible saved. 71a "AKG ENGINEERING HEXICO SA DE GV “Anross Kala; 7712/2008 Talime-Tralning-Melshopa NGI 2. Energy for melting und holding The Eneray requirement for: ‘+ warm up the metal when it is sol ‘+ molting of the metal or the Alloy compound ‘+ and overheat the liquid metal Is depending on the metal, respective to the chemical composition of the alloy. ( Table 1 Heat technical data of different casting metals Metal Melt point middle spec. heat Tomo Gul ligula °c molt point 7 ik mot pglt | aatg"K o Fe [1536 67. (.77 bes (ou jros4 42, (0.50 bos in is, 38, (0.46 fi00 u 60 f,05 1,09 85 ig [650 7 _‘(t,25 60 isi fr4t0 84 B10 i788. n __ p32 21 (0.25 (a [Po 27 03 (0.04 bs The most important task of an industrial furnace is, to bring as effective as possible Energy in type of heat to a good The Energy supply can be done with primary eneray supplies like: Oil, Gas and Coke or with Secondary energy which is electricity “alime-Traiing Melihop-Eng-compldos oe "AKG ENGINEERING MEXICO SA DE GV "Andreas Kates; 71272008A 2.4 Primary energy carrier 2.4.1 The perfect combustion The heat is technically applied to the vast majority by burning of solid, liquid and gaseous fuels produced from air intakes. This produces gaseous combustion products. The main components of all major fuels are carbon and hydrogen C H, can also contain a small quantity of sulfur S ‘occur. These elements react in the fuel during combustion with oxygen from the ambient air and put it in greater quantity of heat energy is released. This may the volume of exhaust gases, depending on the chemical composition of the fuels will remain the same - or even bigger. The quantity of heat generated by the incineration of a certain quantity of {uel released is determined and has been summatized in tables. in Table 2 are the calorific values of the easiest fuels to various units in terms specified, The table can be seen that if only to carbon monoxide CO burns, less than one third of the combustion heat is released, When Burns is theretore a perfect combustion individually, ie Combustible everything is on CO2, H2O and SO2 burnt, there sino soot, nor are flammable gases such as CO, H2 , CH2 contained in the exhaust. ‘Table 2 of the simplest calorific tuels - in terms of different units aloe Ve in MJ c CO | upper tower 8 km 42 | 28 [2877 2426 | 2076 kg 340 | tot | 1427 1203 | 93 n= 1m? te2_| i27 | we 48 | 133 2.1.2 Oxygen and air requirements for solid and liquid fuels The oxygen needs of a perfect combustion results from the composition of fuels. You can see the composition of the fvel in GT paris for solid and liquid substances, or components in space AT substances in gaseous state. The minimum oxygen requirement Oninis to perfect the combustion unit of the fuel according to the chemical equations being required amount of oxygen. Since air only about 21 Vol -% oxygen which is the minimum air requirement for ‘complete combustion can be calculated. 2.1.3 The imperfect combustion Previously, the perfect combustion treated. With no air or insufficient air over the burning remains imperfect. The flue gases contain CO, H., CH and other hydrocarbons, and soot. Also, ‘a cooling of the combustible gases in the combustion chamber under its ignition temperature can lead to oxygen in the exhaust and unburned located. Regular monitoring of flue gas through chemical analysis or the use of independent auditors flue gas, the oxygen content display is recommended. As a tule, the excess air being kept so small that nothing in the unbumed flue gas occurs. It reduces the excess air too much, so the combustion is incomplete, there are chemical calorific losses. Increases it to grow with tho greater quantity of the flue gas losses, physical calorific losses, The physical losses are however less important than the chemical calorific losses, hence itis recommended that with a bit of excess air to drive, Tate: ig Melishop-Eng-compldoc aa "AKG ENGINEERING WEXICO SA DE Cv ‘Androas Katoja; 7122009,AMI In Table 3 you can find the time for melting and warming of nonferrous alloys most commonly used fuels, coke, now plays only a minor role, their composition, the air needs, their lower calorific values and the practical efficiencies listed. -10- ‘Table 3 Overview of thermal properties of fuel for melting and warming Type of te Natural Tiguld Gas] loot Energy Cot ou Gas. Propane Butane | Power jos -o7e a2-a50 [GH a2-90 [Esty [Cathg o.2-0.9H% t-te fata tan 0.8-2.00, regarding vote ; f.0-1.3N2 oinsieos recone in% composition sn volatile Mass fractions components n% os-20 [Mass trations in 6 ie txms of unit 0 6 me 9 to | hw Nirimum ar T7ERNT | BATA eet 27 kg tool | 11,2 mrkg fuel | 89 mir fuel | 24,27 | 32.2 077 i Ig tuol_| kg uot Five gas dy te 805 2a; | 204 1 Fluo gas wot 208 oat 22 | m6 lower Catto 3000 20000 41870 : as060 | aseaa | So as 7 ste20 | rors | 119860 pracize texmat i : z _ as pees 60% 60% 00% coe | -so% | ~t00% etieatve thermal : eae 20% 25% 25% 25% | 25% | ~s5% 2.1.4 Ignition properties of gases Under a gas ignition air mixture is the lowest temperature at which the burning velocity is the same size that the developed heat the heat to the surroundings and the excess heat without combustion by itsell progresses. The amount of the ignition temperature is determined by: ~ The type of fuel, ~The fuel gas concentration in the mixture with the atmosphere and - From the pressure. In response, the intermediary water vapor content of the gas has an impact. in addition, it depends on the external conditions, such as the heat capacity of the room and from the ignition. “atie-Training Mel iop-Eng-compldoe Tors "AKG ENGINEERING MEXICO SA DE GV ‘Andreas Kateja; 71272008,a NSIT Table 4 ignition and burning properties of gases ae Lowianition temperature] Mextgnion speed | manfon zone irin-6Cin oxygen | fiinem/sOnygeninen/s | invors |Carbon monoxide 610 590 33, 110 12,5-7,5 Hydrogen 510 450 267. 890 41-75 Propane si0— 400 [22 a7] a-95 Butane 490 460 30, 350 45-85, Gas 670 600 50 310 45-13,5 The ignition performance effect as follows: - The lower tho ignition velocity, the more unstable the flame, they can stand out from the burner or demolish. It must therefore take measures such as reducing the flow velocity in the gas and ait is taken. - Ahigh ignition temperature makes the ignition. By the close ignition area the setting of the gas- ait mixture to achiove the desired flame image and thus the ‘controllability of the bumer restricted. 2.2 Secondary energy Electricity is a secondary energy and will be in Germany from 30.0% coal, ignite 25.3%, natural gas 16.7%, 11.9% nuclear, oll, 6.6%, hydropower 5.1% and other imports, including 4.4% produced. The thermal efficiency in the production of electrical energy from primary energy is now about 40%, The average effective elticiency of an electric furnace is approximately 65%. The utlization of primary energy is thus the use of electrical energy for melting and warming only around 04 * 0.65 = 0.26 ie 26% For metallurgical, operational and environmental reasons, the electrical energy are used increasingly also In nonferrous metal foundries for melting and warming. For exact cost comparisons of energy prices in the Melting area is in any case an exact calculation of the involvement of the different investment and accurately valued advantages, such as controllability and implement burn up. ‘There currently is still the founder rule: Primary eneray to melt Secondary energy to holding on ‘alime-Trainng Motihop-Eng-compldoe We [AKG ENGINEERING MEXICO SA DE GV ‘Anctess Kaloja 71272008,(SIS oa 3. Furnace 3.1 General requirements The goal of every foundry is a metallurgical unimpaired, economically smelter. it is operating, maintenance and cost of the smelting plant to be small, the pressure on the environment, the statutory provision, the conditions at the workplace and the operation have to be optimal. In the furnace, especially for printing and permanent mold casting system, throughout the work shift cast able metal ready to stand. For warming is often gas, oil or electrically heated furnaces with basin or pot formed metting space. Occasionally you will also fuel heated open-hearth furnaces with lateral pockets for removal of the metal or, particularly in small foundries, ‘combined melting furnaces and a. Hlent way for nn shieved with these ovens To create a uniform bath temperature and to reach a good temperature control is necessary, against gas absorption and oxidation of the melt, measures must be taken, In small and medium-sized alloy foundries play crucible furnaces with loose crucibles for melting and warming, an important role. These ovens are in relation to the capacity and melting performance very adaptable. The treatment of the melt can be easily carried out, the pot can be easily cleaned, For sensitive alloys crucibles ductile and special crucibles are used. In fuel heated crucible furnaces the investment costs are relatively low. It should be noted, however, the cost of the pot. In summary, in a furnace for nonferrous alloys to make the following requirements: High melting capacity 2. Good temperature control Low burn up High thermal efficiency Easy to operate Easy loading Slight deduction scabies . Ease of maintenance Fast Alloy Exchange 10. Peaceful melt bath skin in good melting mixture 41. Operation Independent CeNensenn Facilities should also be present, how the inclusion of the hydrogen in the melt and metallic or non-metallic imputities can be avoided. 3.2 Combustible heated melt & holding furnaces The fuel coke (coal) has faclities for melting non-ferrous metal foundries no meaning anymore. The heating with coke is for small smelters technically and economically obsolete. These plants would not meet the requirements of the Temperature adjustability yet, since the heating of coke produced much dirt with the requirements of the TA-Luft requirements. Even urban, long distance and coke-oven, gas to have hardly any importance. As a bumer for oil and gas firing, set up: mpldoe aa "AKG ENGINEERING HEXICO SA DE Cv ‘Andreas Kaela; 7712/2009 inlng-Molishop-Eng:ASI oa - Manually, so-called low-pressure bumer The fuel is nozzle formed on a pipe or a nozzle body with several openings to the mixing area of the bumer fed. The flow of combustion air is arranged by a separate blower add mixed. By regulation valves can the flame shape and the performance may be changed, eg at: Oil in the ratio 1:4, for gas 1: 10 the oil pressure is between 0.8 to 0.5 bar the gas pressure from 20 to 30 m/ bar the air pressure between 40 to 60 m/ bar ‘The ignition is carried out with fuse by hand or by a separate pilot burner, the flame monitoring requires separate accessories. - Fully automatic burner with Oil feeding through a nozzle or a nozzle body in the mixing tube. ‘+ the oll pressure is 8 to 15 bar, the gas pressure in gas 20 to 30 m/ bar, * barometric 6-12 m//bar. The regulation is done with oil on the pressure in gas through valve adjustment. The combustion air will slide or tlap setting regulated, The ignition electrode is carried out by mixing in the area at the beginning of flames. The flames are mostly by UV diodes monitored. With gas burners will also burner with premixing of the gases A. It differs from the combustion of natural gas with Premix: - Pressure or propellant gas jet burner, with a gas pressure from 0.3 to 0.6 bar as a propellant and the combustion air (9-fold volume of air) after the Bunsen principle suck. = Gas-ait bumers are operated with compressed air. The gas pressure is about 0.02 bar, the air pressure around 0.5 bar. Airis used as a propellant, - Brenner, a centrally pre -yet non-flammable gas-air mixture burns, the pressure of the mixture is approximately 0.2 bar and sucks secondary air after the Bunsen principle. In stove and tank furnaces are also without premixing burner, eg Parallel and cross-llow burner. Some furnace supplier use also high-speed burner. 8.2.1 Crucible furnaces In most non-ferrous metal foundries are crucible furnaces to melt and warming be used. Depending on the energy are oil or gas furnaces installed. As more heat energy heating the furnace chamber can be fed, the melting rate of oil heated smelters is around 10 to 20% larger than comparable gas-fired furnaces. The bum will depend on the nature of the host material, the furnace size and the melting practices. Itis with 1.0 to 2.5% is relatively cheap. Talim ining Halichop-Eng-compldoe 878 "AKG ENGINEERING NEXICO SADE GV ‘Andreas Kateja; 71272008,ut INIA ‘The fuel heated crucible furnaces recoverable Quality the melt enough in susceptible alloys (e.9. ‘AINgs, AICuTi, CuAl leg.), Even properly functioning and appropriate cleaning and degassing treatment fullils the highest requirements. {t differs in furnaces with ductile and fixed crucibles. Crucible furnaces built as pot or ladle furnaces and are considered primarily as a tilting crucible furnaces produced. ‘While generally regarded as ladle furnaces crucibles used in titing crucible furnaces the molten metal. Tilting fue! heated crucible furnaces have a capacity to approximately 350 kg aluminum and a melting capacity trom 100 to 220 kg / h. Crucible furnaces with a larger capacity is less recommended. Crucible furnaces with ductile crucible have the advantage that the ladles by refiling hence the pollution caused by in a shored Oxide skins and the resulting Heat loss. If for sensitive alloys separate pot made available, can be no contamination by undesirable alloying elements occur. The pulling of the crucible and the further handling, however, poses some dangers. With respect toa convenient handling, the capacity of a ductile crucible max, weight of Alloy is 100 kg, ‘The bumer types are available in the recent years have been greatly improved stoves and often with an automatic temperature control system. Since automatic rules by throttling the fuel supply because of the necessary resetting of the alr ‘would cause signiticant expense, itis usually after the simple on-off ‘method. For larger fuinaces ‘can order a more even heating beneficial to have two burners to use, including one over the larger base and the other after the on-olf procedures, the rule load. Essential to the crucible durability is that the flame is not directly burn the orucible , but the flame ‘exhaust have to envelop the crucible "soft". For gas-fired ovens have stone jet burner because of their high efficiency and especially because of the high radiation area well. Even with gas burner slit opening are beneticial. In Figure 1 are the type’s fuel heated fumaces presented. Figure 2shows a technically optimized heat oven. SY SWI Feslstohender Tiegolofen Tiegel'relstehend, Tlegeleistehend, Tlegel eststehend, mit abgemauertem Abluitétinung seltiche ten kippbar Tiegel Im Decket Ablutttinung Figure 1 Models of crucible furnaces ‘Tatime-Tralning-Mishop-Eng-comphos ara ‘AKG ENGINEERING MEXICO SA DE CV "Andreas Kaeo; 7/2/2009ut ANSI Yeeannuage: ennai Rekuparatedvanset Figure 2 Heat Technically optimized crucible furnace 3.2.2 Dealing with crucibles For warming and melting of aluminum mainly crucible furnaces are used. The crucible is used, by the following tasks: + high thermal conductivity + Resistance to attack by molten, slag and Others Use products + Resistance to mechanical stress + Transport and storage capacity Mainly in fuel or resistance heated furnaces following types of crucibles found: + Ton graphite melting pot - High thermal conductivity = For all Oven systems and all non-ferrous metal alloys used - High-pressed Ton graphite melting pot - Under high pressure pressed Ton graphite melting pot, have a very dense microstructure = Very good thermal conductivity and short heating times, - Low porosity with a consequent high resistance to metal oxides and melt treatment substances (chlorides, phosphates) - For melting furnaces and aluminum alloys suitable for * SIC crucible Carbon-based Melting Pot Very high oxidation resistance - Very high thermal conductivity - High thermal shock resistance (through carbon sequestration) - Higher floxibiity and quickly to heat ‘atime Training Molishop-Eng-compldoe wrag ~ AKG ENGINEERING MEXICO SADE Gv ‘Andreas Kaleja 7122008,Possible damage to crucibles: Transport damages by miscalculated built Crucible wrong pot saucer wrong Charging /fiting wrong ait, poor leadership flames by oxidation of the refractory material by wrong tools Slag formation and melting preparations Damage caused by incorrect crucible transportation or installation ‘A melting pot, whether ton graphite bonded or carbon bonded SiC crucibles, is particularly sensitive to shock, impact, hard touchdown, large temperature fluctuations (temperature shock). Shockclike strain can contribute to the formation of hairline cracks, which during heating of the crucible bigger and destroy him, Shipping damage can be sudden Loads during transport, transport by roling, non linear touchdown, unpadded induce transport tools. Therefore crucibles must always be handled with suitable means of transport such as: + Stacker (pot on a wooden pallet with a buffer material) + Grane (handling tool with rubber cushions) + Trolleys (padded) Installation Error The classic installation errors at crucibles include the following points: + Lid touchas the crucible. This has the consequence that all the vibrations and stresses of the lid get directly transferred to the crucible. Furthermore, the pot does not extend to the top. It olten follows cracks in the upper circular edge of the crucible. + Crucible is connected to the side edge. This not allows the pot to expand to the top neither to side yor, it creates tensions which lead to cracks, ‘+ Tilting furnace with @ fong outlet spot. Is the outiet spot completely walled in with ramming mass, then depending on the crucible temperature, fluctuations occurring at the outlet spot and it tears. + Cold zones caused by distraction of the leadership or flames hanging fiber mats mean that the crucible wall is not homogeneous from the heat is up, thereby creating tension, r the glaze-pot is not sufficiently heated, melts and the crucibles are not in this field is not estimated from oxidation. + I the pot is not exactly centered in the furnace installed, the leadership of the burner flame is also one-sided, leading to temperature differences and further damage of the cucible can lead. Tension may also occur. Installation options to avoid error - Upper pot edge fiber mat with caulk - Not immure the pot, crucible / pot edge distance from the furnace wall side should be a few om = do not put the Lid direct on the pot rim - The ting furnace, the crucible expansion (a few mm) can (in the board space, crucibles and bricks, burt in the heat of the furnace) ~ Underpin the long outlet spot with fiber mats, do not directly immure with fireproof material, TERING MEXICO SA DE CV ‘Androes Kaloja; 7122000 Talime-Traloing Wollshop:Eng-complidoc 61a ‘AKG ENGINGI aT Wrong pot stand Atoo small pot saucer has the following disadvantages: - The load-bearing surface of a crucible is in the outer edge of the ground and thus the transition to the wall, the pot with a to little ground create a to heavily load on the area. Also an oversized pot standing on the ground gets overheated by the burner flame. - Uneven surface of the crucible is e.g. applied by dividing funds (Cone), the pot of soil is also strongly localized to stay. The material of the pot should stand in its characteristics as regards the thermal conductivity and thermal shock resistance of the graphite-SiC-pot or similar. Improper use of materials Ingots and circulation material should always be careful, with use of a suitable tool, set in to the crucible, These always without harm to the crucible walls or crucible floor by sudden exposure. ‘At very high ovens, the material should be set in by using a caliper, a handling device, Particularly successful has been the onset of the material in a furnace with residual swamp, because the soll pot is already estimated, The residual swamp has other advantages: + Reduced burning + Rapidly melting of the material used + Lower tomperature fluctuations in the crucible + alter filing the crucible it must be continually observed that it is not overloaded. To fil in ingots have some disadvantages: + Metallurgic education in the local cool zones of the melt + crucible, as committing violent ingot of the pot wall may be damaged and also impacted input ‘materials when heating by the forthcoming expansion also damage the crucible. ‘Metal remains in the crucible (swamp), which is frozen, can by the reheating process damage the crucible by their greater extent. Therefore, larger quantities of motals do not remain frozen in the crucible. False air, poor leadership flames As already mentioned, the correct leadership of the burner flame is essential for a proper melting performances, flawless production quality and a satisfactory service life of the crucible. The bummer flame should not be the case: - Directly to the crucible wall meet - By setting the dirty soot-burner, or oll to the pot wall deposition (eg too litle oxygen supply to the burner) + Too short flame just at the bottom of the furnace or the crucible floor area sufficient heat - Increase in supply of fuel, the oxygen or air flow is also adjusted, however, it is important to note that the oven only for a certain power burner is designed, it should be exceeded in the furnace is overheating of the crucible on. ‘Talim Tramning Holiahop-Eng-compldoo 18 "ARG ENGINEERING MEXICO SADE GV ‘andreas Kaloja; 7/12/2009ut AGT A good fire management is that the burner flame to the pot evenly goes from bottom to top, glaze over the pot heats up the extent that this is melting pot and protects against oxidation. Another reason for damage the crucible is the cooling of the burner to prevent it from overheating, alter the melting. This often happens in the furnace instead of directly with the consequence that the cold air furnaces not only the burner from overheating but also protects the crucible wall occasionally very cool. This leads to significant temperature dilferences in the crucible and thereby caused injury to the same. An opportunity is: To remove (portable burner) the burner from the furnace after the melting process. Furthermore, it should be noted that the burner Is always in the optimum is to keep operating, The manufacturer's specified operating data are observed, This not only protects the crucible, but also ensures that the optimum melt and inexpensive can be used. ‘The emergency spot of a crucible furnace must also be closed as far as that does not leak air from the outside through the crucible and temperature fluctuations can cause damage. Oxidation of refractory material At SiC crucibles happen cracks in the crucible when the existing SiC with oxygen to SiOzoxidized. SiOz has a much greater exten! than SiC, thus formed in the crucible cracks. When graphite crucibles, the oxygen with the graphite to CO2 respond. This leads to the flaking of the glaze on the pot and its destruction. Here are some ways the oxidation of the crucible to avoid: - Crucible furnace should be closed and protected against oxidation - Mechanical damage of the crucible when inserting avoid rucible of false front ar intakes to protect this lead to flaking of the glaze, allowing the oxidation of the crucible material = Burners under optimum operating and keep under regular review, it must be an oxygen excoss should be avoided as the discontinuation of soot or Olpartikeln also are flame stitch and thus an Uneven heating of the crucible to prevent. Wrong Tools Liiting devices and tongs for handling of crucibles should be so designed that they do not damage the crucible. Therefore, their diameter should be large enough that the pot is not at the top but below the middle of the crucible can be taken. When you close the pliers, the upper edge of the crucible should not be burdened by pressure Slag formation and melting preparations The slag is firmly connected to the crucible bottom; the sintered crucible wall is often lead to cracking, This Is due to the much higher thermal expansion of the slag compared to the crucible material How to get from the following trend chart can be found growing at about 500°C the expansion of the slag as opposed to the crucible material sharply. Tallme-Tialing Malishop Eng-compldoe Tere "ARG ENGINEERING NEXICO SA DE GV ‘Angreas Kaleja; 71272008. NAMA Slag Strain Crucible / Pot © 100 200 300 400 500 600 700 Temperatur °C If the slag firmly enough with the pot overwinter, there is a danger that the crucible material during heating tears, In addition there is the danger that aluminum stag in longer service lite of the crucible from the ambient air moisture (greasy slag layer). During heating of the furnace, the forming hydrogen to damage the aluminum melt at, or in correspondingly large amounts of hydrogen deflagration and pot can harm. Au fk - Clean Pot regularly after each emptying of slag remains, taking care that the crucible wall and bottom of the pot evenly cleaned. Even thin layers of slag leads to reactions between slag and le glaze, which al later times, makes the removal of the slag much more difficult. ~ To purify the appropriate tool must be present; the operations should be managed by experienced professionals. When removing the slag the tools must be used so that the pot is not damaged, To melt treatment set of aluminum melt prepatations (salts, detergents, processing resources, ‘etc,) can cause damage to the lead pot. To prevent this should be observed: Preparations always melt until molten material to enter (lower reaction time, better inclusion in melt) ~ Salts should not be in a diving bell for too ong in one place the pot of soil still inger in the treatment of the meit with the crucible wall react - To the one-sided sub-cooling of the crucible wall to be opened to prevent the reaction gases is always centered in the crucible will be introduced, wre "AKG ENGINEERING MEXICO SADE GV "Andvess Kalla 7/2/2009a AGT 8.2.8 Open- hearth fumaces The essential feature of these furnaces shows Figure 4: = Large opening of the furnace chamber to use coarse material - Large bath skin in relation to the melting of the bath depth or volume = Good heat transfer through direct admission of the use of the flame exhauts - Harder alloy Exchange, suitability for low-burn up, gas sensitive alloys. pou ‘iru Figure 5 Schematic diagram for the integrated metal preheating (type: Striko, Wieh!) “alime-Talning elishop-Eng-compl dos 20788 "ARG ENGINEERING MEXICO SA DE GV ‘andreas Keoja; 7/2/2000IMA Open: hearth furnaces have a high furnace roof, the flame acts in parallel to the sufficient amount bath skin / surface. The possibilities for treatments in the melting fumace are limited. However, this in size from approximately 0.5 to 20 ton capacity ovens built large amounts of ‘metal quickly and economically to melt. They can also be used for coarse scrap re-smelting. te Ina 2.5 t-0.5 toven aluminum can in 60 minutes for an oil consumption from 50 to 60 kg will be melted. To meet this warming oven 9 kg of oil /h, When fuel gas is increasingly used. Hearth fumaces are fixedor filtconstructed, with the latter execution necessarily one is preferable. Very often, the open hearth fumace is provided with a melting bridge. This has the advantage that apart from the normal material also more polluted, with iron or such parts can be used effectively. From the melt bridge flow's melted alloy off in the furnace room, whare the iron oxide residue and parts can be deducted. Large hearth furnaces are also used for the liquid metal supply. 3.2.4 Shalt ovens In this furnace the combustion gases increase in direct contact with the use of material from the bottom up. The use of metallic = Is at the top of the slot in the cold condition + Cut the rising exhaust gases whose heat + Decreases in the shaft itself down and warms up here. Shaft furnaces work on the counter flow principle and therefore they are heat technically economic Their relatively large melting rate reduces the contact time of flame exhausts with the metal, so the burn is within reasonable limits The feedstock is abandoned and reaches above the melt to a melting bridge, of which the share has become redundant flows in the underlying collection room and the holding room. These ovens aro usually fixed with a plug valve, They have capacities from 5000 kg to 30000 kg alloy and melting benefits between 500 kg and 5000 kg / h. For alloys of the type AlSiCu these furnaces have proven satistactory. Technically, you should operate the tiling execution preference, 3.2.5 Drum, Pan, Round melting furnaces ‘These types of furnaces are mainly used in metallurgical, semi-and smelters. in drum furnaces are filled with all kinds of sorap, turnings and other oily processed. You can accommodate from 1 t0.30 tons, including the amount of salt, you have, 20-30 mass% of the total use of material is aluminum. Depending on the melting performance, Furnaces sizes between 0.5 and 8 t/h are achioved. Tollme-Traring Walishop Eng-compldos 2178 "AKG ENGINEERING MEXICO SA DE GVAi Schmelee == Honente (ri ml | Aboas, 4 Figure 6 rotary drum furnace Through a tong life of the refractory material and a very stable furnace construction distinguished from the bath furnace. When the furnace has a capacity of up to 50 tons and is preferred to melt, as well as mixers and converters. The melting capacity is, however, in relation to capacity is low. tis only up to 5 t/h. The coupling of gas with heat management factities is supported by the furnace construction is difficult. Verbrannungslutt Figure 7 Bath furnace tit Additional equipment at the big size furnaces faciltates the manageability. Known examples Level indicator ~ Temperature monitoring equipment + Filter locks in front of the metal extraction points The Round oven (Figure 8) allows rapid charging and high melting porformance. In practica, furnaces with a capacity of up to 60 t and melting performance of approximately 10 to 20 t/h in use. Through the talk or movable dome lid can also large and bulky parts, and on pallets or in containers collected material circulation in the oven will be introduced. The shape of the furnace Talim Training Helishop-Eng-compldoo m1 ‘AKG ENGINEERING MEXICO SA DE CV ‘Andros Kale; 71272009,a A&M and the tangential burner arrangement, have favorable effects on the durability of the lining, ‘Smaller kinds of this type (5-10 t capacity) are often hydraulically tited with an melt outiet spot. In trays and round ovens, especially open hearth furnaces have high-speed burner through the heat transfer increase the melt speed. They are supplied with cold or warm air operated burner. The burners are either incorporated inlo the furnace lid and blow then diagonally to the bathroom, or they are built into the side and are sight tited to the bathroom, Figure 8 circular furnace with removable roof and tangentially arranged burners 8.2.6 Holding furnaces Oil heated or gas heated furnaces are primarily as Crucible furnaces but mostly with new automatic temperature control and automatic working burners with a capacity up to 1000 kg of aluminum. The charging of the furnaces with molten metal that comes from a pre smelter. The separate melting and warming should always be sought. This approach allows the {umace an appropriately treated with clean metal temperature of the proposed procedure. For sensitive and alloys, where special demands at the cast pieces are given this way of working is imperative. 3.2.7 Combined melting and holding furnaces. The aforementioned gas or oil heated crucible furnaces are olten also used as a combined melting and holding furnaces. The advantage is that a separate pre smelter and the transport of liquid metal is deleted, There are some limitations compared. For example, the treatment options for the melt are limited, and also in terms of temperature control which can be used are limitations. It should therefore only clean block material be used, and also it should be avoided, regularly and at appropriate intervals, to strong temperature fluctuations, The disadvantage of this approach is that the melt not only by the removal of metal is moved, but also through the ‘ongoing us ftom cold to melting material. ‘Talia Talning Meishop Eng-compldoe Brae "AKG ENGINEERING MEXICO SA DE CV ‘Andreas Kaela; 7/12/2009AIS In the melt in washed Oxide skins can hardly come off. Through the use of cold block material are also sub-cooling zones created by liquate of strongly encourage intermetallic compounds (hard points in the component). The use of simple filter devices (screens, fibreglass fabrics, ceramic filters) provides Partial protection against such segregation, The bath surface should always be cleaned. For larger metal needs, open-hearth furnaces as well as combined smelting furnaces are used. These are then connected to one or more collection bags for the metal 3.2.8 Oxygen-ontiched combustion air to melt The old idea and way of natural oxygen, which are about 21 vol. %, to increase and thus a better utilization of energy to maintain, was also used for the smelting of nonferrous metals ever again. Jn general, an O2-enrichment at about 28 vol. %. This results in a higher melting capacity. The oxygenation promotes the combustion of the hydrocarbon feedstock introduced (loop material from pressure and permanent mold foundries with oil allachment). The occurrence of black smoke cloud (Environment) is a rapid and complete combustion of these hydrocarbons are avoided. The technical capabilties of the oxygen enrichment of combustion air should be further explored and the efficiency calculated. 3.3 Electrically heated melt & holding furnaces The major advantages of electrically heated melting and holding furnaces are: - Favorable metallurgical properties + (Especially for sensitive alloys) - Low to very low burn up - Low gas consumption - Good Temperature adjustment = Clean working methods - Low operating costs = Good adaptation to the operating conditions, economic way of working, even with portable power - Environmentally friendly, However, offers an electric furnace alone is no guarantee of a clean, in the technical sense gas {ree & oxide free metal. It creates the precondition for that with good equipment and good use of melting technique flawless melt is prepared. ‘The disadvantage is the relatively high procurement and in comparison to other high cost energy sources for electrical energy. “Talime-Traling Malishop-Eng-commpldos Tae "ARG ENGINEERING NEXICO SADE CV ‘Andreas Kaela; 7/2/2008AGT 28 3.3.1 Resistance heated crucible furnaces Due to their low melting capacity resistance crucible fumaces have a little meaning today. This statement is true for the metallic resistance equipped furnaces. These heaters allow only about 50 KW to 1 m® Heating installation There are also resistance fumiaces with SIC heating oloments on the market. With SiC heating ‘elements can be benefits to about 150 KW / m? install. Isotterung.—| Bodenousktetung, 4 oe 2 Weems 4 Oleabtnnens 8 tenner Figure 10 assemblies of the SiC crucible furnace 8.8.2 Resistance heated open hearth furnaces For pure furnaces here is the same as for crucible furaces. They have, however well as mixers and large fumaces proved. As such, often in large foundries can be find resistance-hearth furnaces with capacity of up to 6 t The disadvantage is the sensitivity of the ceiling to metal dashes. The heater coil is protected through the tube. The relatively cheap steel pipe can be easily replaced. SiC heating elements are less sensitive to metal dashes. Smaller foundries have open hearth furaces installed with resistance heaters to use the cheap night electricity Tatine-Trahing Malishop-Eng-compldos Tae "AKG ENGINEERING MEXICO SADE CV “Andreas Kaela ; 771272000IAG 3.3.3 Inductively heated furnaces 8.8.3.1 Launder-induction Gutters-pure induction furnaces are not particularly suited to them as such are therefore also not used in foundries, however, as big size furnaces lodge in foundries. Because of the electro dynamic forces, the impurities, especially the oxides, rinsed in the gutter and are then fixed. These approaches need to be continuously removed with suitable tools, in order to ensure an undisturbed kiln, At this necessary and cumbersome gutter cleaning more, that trough with cokd induction not use and can be approached over a longer operation breaks out must be warm. In large aluminum foundry’s, for many years, are large, 8-12 tmaking, induction Launder furnaces as mixer or as a collector, some with pressure gas emptying, be used. These ovens cover the liquid metal, ate also preferably used in such foundries, (Pictures 17. to 12). In recent years the development was designed by renowned Furnace designer to improve the construction of the inductors, By changing the shape of the gutter and the arrangement of the launders a flow of liquid metal through the launders in a given direction is enforced Instead of the familiar throbbing of liquid metal in the gutter with inducers of old design (Figure 12) is now facing the flow of modem inducers. (Figure 13). Wy \ Nh LK i it fal i tat ey Ly rs ee eC wi WIC SIC Figure 12 Inductor old type (metal pulsating Figure 11 Launder inductor furnace flow) Image 13 Metal flow in a modern High power inductor furnace “alime-Tralning Welishop-Eng-compldoe 21a "AKG ENGINEERING MEXICO SA DE GV ‘Andreas Koleja; 7/2/2000i NGI ‘The high speed of the metal flows from the gutter branches in the melting area of furnace room, makes a good mixing of the melt even when ALLOYING. By High power inductor the economics of the channel furnace in the following ways: - The performance of a Inductor unit shows a melting capacity of about 2.31/ h without idle times, in use of the furnace - The specific melting power is reduced - The utilization of the plant will be improved - Labor costs have been reduced = In flow of small sized scrap at low filing is possible Tallme-Traling-Welishop-Eng-compldoe ara ‘AKG ENGINEERING MEXICO SADE GV "Andee Keele; 7/2/2009a NEI 8.8.8.2 No launder induction NF-crucible furnaces The Low frequency Induction crucible furnaces are developed since 1950 to very good and efficient metting units and found in medium and large enterprises a significant and increasing use. These furnaces are used for shape casting with crucible content from about 500 to 3000 kg aluminum produced, services melting at 260 to 1250 kg /h and a Power Consumption from 520 to 600 kg aluminum kWh/100 in relation to the melt bath temperature of 750°C. The compacted, ceramic pot, possibly with a saline-crinoline salt impregnated mixture is smooth and easy to clean, so that an alloy change in many cases is simple. The durability of the crucible may amount to more than 10000 batches. There have been developed now also finished crucibles for induction furnaces in which the crucible with the help of relatively simple pressing devices alter “end of lifo” in a piace of the coil may be ejected. This device has a strong help in the delivery of induction furnaces kept changing. The fear that the melt / bath moving leads to a imploring of oxides, has been practically proved to be groundless. Once the bath moving by an appropriate interpretation of the furnace (in a geometric and electro-technical terms) is limited, and secondly, the oxides and other nonmetallic impurities, by bath moving to certain parts of the crucible flushed where they fix and clean the crucibles are removed. This is a remarkable sell-connected melt The bath moving also ensures good mixing of the melt, so that both composition and temperature is uniform, For alloy bath moving work supports the rapid dissolution and uniform distribution of the added metal in the melt. The melting treatments are easy and convenient to carry out. The burn time depending on the type of material in general use about 0.5% to 1%. With help of the new static frequency converter, these furnaces can be run with 150 or 250 Hz. ‘Therefore are more options regarding to smaller volume, the melt power and the bath moving, A special design, the so called “Short coil furnace” that itis in principle an NF-crucible fumace, but only with a short coll atthe bottom of crucible area. These ovens can be found including the Use as large furnaces. The construction of a crucible induction furnace shows Figure 14. alive Taking Melishop Ena: compldoe Tee ‘AKG ENGINEERING NEXICO SADE CV ‘Andreas Kaela; 7/2/2000Bild14 building a crucible induction furnace The bath moving in ‘@ Induction ctucible furnace is the Figure 15 below. The Bath moving depends on the frequency and power consumption, with the same power results in a higher frequency and a smaller bath moving. Oxidhaut (Schlacke} Schmelze KKK SS OE N N N N N N N N N N N N N N N N N N N N N N % Figure 15 Bath moving in a Induction crucible furnace ‘allne-Taining Walishop Eng-compldoe 1 "ARG ENGINEERING MEXICO SADE GV “Andreae Kaloja; 7122000,a AT 3.3.8.3 MF hoods and Lift crucible furnaces The medium-frequency crucible with loose cover (Figure 16) represents perhaps the electrical equivalent of the fixed gas or oil heated crucible furnace with lift able crucible. Liability for melting smaller amounts to about 80 kg aluminum, it forms in many respects almost ideal furnace. Figure 16 Arrangement of a medium-frequency hood Induction crucible furnace Unfortunately, the cost of such a fumace, regarding to the need for a medium frequency converter, are quite high. For smaller amounts of melting up to about 200 kg copper alloys, itis one in many respects almost ideal furnace. wt yy enerthiche Image 17 A twin lift induction crucible furnace Halishop-Eng-compldoo wre "AKG ENGINEERING WEXIGO SA DE CV ‘Androas Kaloja 71222009,a AAT ‘The center frequency is produced by static frequency converter generators. These ovens have been in heavy metal foundries are well established and also for the smolting of aluminum. 8.3.4 Resistance furnaces Resistance furnaces with graphite, silicon carbide or Grey Iron pots have been proven. They are usually for a capacity up to about 300 kg aluminum connector and a value up to about 40 kW chargers. The Temperature adjustability is very good. Apart from heating wire spirals are ‘especially rim formed heaters proved excellent. The investment costs for these kind of furnace aro relatively iow, as is the electricity, as pure holding unit the necessary energy input is small It itis the metal removal allowed for the sake of energy saving furnace with a lid, be the means of a simple pneumatic or hydraulic device, such as by feed \oping for metal removal can be removed. This furnace is also used as casting furnace for the low-pressure permanent mold casting. 3.8.5 Inductively heated fumaces The casting capacity in foundries and the casting pressure are in part so strongly that furnaces with a capacity of 300 kg are no longer sulficient. For large amounts of warming as already mentioned launder-induction furnaces with a capacity from 700 to 1500 kg and port values from 40 to 75 KW are very well ‘On the side of the compacted crucible formed furnace pot, is at an angle of about 10° V-shaped gully, with trained melting plugs arranged. It allows easy cleaning of the two straight launders as well as the complete emptying of the furnace. Since this furnace only with pure liquid metal numbers, is the Oxide deposition in the gutter low. A cleaning is usually necessary once a week. In contrast to the resistance furnaces are the gutters are induction holding furnaces but only for continuous operation. They are given for large foundries furnaces with corresponding casting program. As big size casting furnaces for the low-pressure permanent mold casting have this type of furnace done very well. 3.3.6 Combined melting furnaces and The principle of the induction furnace troughs allowed combined smelting and melting furnaces with separate rooms and to build two chamber furnaces. Either a more oval or rectangular tub with bottom vertically arranged melting troughs by a divider into a melting and gather subdivided space or the adjacent enamel and metal extraction space is filled with the almost horizontal enamel gutters connected. These furnaces must be equipped with liquid metal approached and operating over shorter breaks will remain warm. An alloy is a complicated change, ‘As with fuel heated combined melting furnaces and the main advantage is seen that a larger pre- smetter or a liquid metal transport is deleted. Since the melting treatment options are limited, must be to a satisfactory quality of metal to secure, clean metal to be sot. The setting must be possible after all 5-10 minutes in small quantities (corresponding to the metal removal), «a sufficiently uniform holding temperature in the gather space is to reach. ‘atime: Tralning Molishop Eng-compldoe a7ae "AKG ENGINEERING NiEXICO SADE GV ‘Andreas Kaleje 57/12/2000a NETS Besides the “classic” Crucible Furnace are also furnaces with no pot as gather furnace in Bath-/ chamber- or pot form. The heating resistor is located on the ceiling. These newly constructed stoves usually have very good heat insulation. Even through a small metal removal opening the energy minimized. There are very favorable energy consumption figures. However, the small Port values no after melting, and also a heating of the melt iasts very long. 3.8.7 Other furnaces 4, Liquid Metal Supply Large foundries and medium-sized foundries get delivered out of smelters a large part of the Fequired metal in liquid state. in tetms of liquid metal is a limitation to max. 2 alloys recommended, The transport occuts in approximately 3-4 tons of metal-making and very well insulated pans with road vehicles. The distances are 200 km, more. In rare cases, the liquid metal also transported over 500 km. The temperature of waste is approximately 15°C to 30°C. Through the delivery of liquid metal in the smelting plant and ingot casting in foundry smelting saved. In the foundry must be large furnaces and collectors are ready to set the incoming liquid metal to take over. It also requires a corresponding iting and roofed-over points ahead. An additional advantage is the high quality of the incoming metal. = Through the long standing time = The provision of the melt in the melting plant (smelter) = The consumption in the foundry ~ By the vibration effect atthe transport 1s the melting largely free of nonmetallic impurities, The liquid metal cover is only economical when large quantities once a day, approximately 12 t or more, calculated, and these quantities on the same day will be encapsulated. A warming about 24 to 36 hours is uneconomical. Since about 50% starches material cicculation, must also be a correspondingly large melting capacity is available, not least to secure the metal supply. A. molten metal supply must be very careful technical and economic planning. Tallme-Training Maliahep Eng-compldoe wae ‘AKG ENGINEERING MEXICO SADE GV ‘Andreas Kala; 7/1212000Chapter C Melting process from non-ferrous alloys 4 Problem of non: fous metal smelting 2 Molting technique of aluminum alloys 2.1 Feedstock’s 2.2 Fundamentals of Melt Treatmont 2.3 Melt Treatment Funds 24 Degassing method's for aluminum alloys 2.5 Cleaning methogs 2.6 Palit tetining 2.7 Melting process and treatment monitoring 1. Problem of non-ferrous metal smelting Both technically as light construction materials disseminated ‘Aluminum and Magnesium and its alloys react-particularly intense at higher temperatures with the oxygen in the air, some with alloying elements and other substances. In addition, in principle, in casting alloys smallest quantities of contaminants in the torpor in certain areas and enrich the material properties subsequent damage, In addition to the strong reaction of all non-ferrous metals (including copper casting alloys) is its temperature-dependent solution for asset gases is a major concem during the part generation, For these and additional reasons, the technique of smelting aluminum and magnesium alloys, an Inoreased attention. The provision of non-ferrous metal smelting for the production of high quality castings is not a simple re-melting but requires careful metallurgical knowledge and work tasks ahead! 2. Melting technique of aluminum alloys 2.1 Feedstock’s The recommended method of melting lead is essentially dependent on the external nature of the missions. Dirty or corroded materials where possible to pre melt. Only clean material can be used directly in the crucible of casting furnaces. However, the refill amount be calculated so that the temperature fluctuations are kept within lits. Segregations, i.e, Accumulations of high-melting, hard alloy components in later casting ‘microstructure are stil in the presence of Fe, Mn and / or Cr hardly are avoided, Corrosion on aluminum as a white dot lining is often only visible from the water, chemical reaction products consists of aluminum. The corrosion caused by moisture in, for example "aiie-Talning Mollahop-Eng-compldoe Brae "ARG ENGINEERING MEXICO SADE GV “Aneroas Kala; 77122000NETS Improper approach to storage, transport, or by condensation. Corroded material must be made before use in the melt always carefully preheated, since the aqueous corrosion products usually get their water only at temperatures far above 100°C competence. Too strong in spite of corrosion can be pre-heated steam as development that melt explosively hurled out of the oven is. m4. runs the following reaction, 2Al + 3H°O=>Al208 + SH This shows that corroded material not only brings hydrogen into the melt, but also makes the flow ability of the resulting aluminum bad. To avoid violent reactions in the melt heavily corroded material should be melted only in an ‘empty pot, and carefully cleaned and degassed. Adhering to core and molding sand to reusable loop material can lead to a low enrichment of silicon, but only in particularly sensitive alloys, such as the G-G-AlCu4Ti or AlMgi0 can be harmful, I in a number of foundry alloys and molten shed (which is usually the case may be), 80 great care is to: + labeling + pure storage and reuse Circulation of materials to make them the accidental mixing of the alloys can be safely avoided. Even very small percentage levels of Error elements may melt in substantial harm! Casting remains from the high pressure casting are due to thelr often considerable lubrication attachments a very heavily soiled use, for which a pre melting furnace is strictly necessary. The ‘melting of chips and dross's for the foundry is usually not worthwhile, they should be aligned with the metal block manufacturer for reprocessing to be. Particular care should bo based on an alloy segregation in the storage are respected, so that confusion does not happen here. tn particular, the metallurgical alloys with max. 0.05% Cu is in the casting of Cu-containing materials is kept separate. The same applies to the separation of high-purity alloys for high strength requirements, both among themselves and to other aluminum alloys. Especially in pressure foundries, including zinc process, there is a danger of ‘mixing with zine. Some% Zn embitterment effect on aluminum alloys. paration of the material is only available, albeit in furnaces, crucibles and tools of ss" should be avoided. Tallmo-Traling Hatiahop-Eng-compldos Te "AKG ENGINEERING MEXICO SADE GV ‘androas Kaloja; 7122000,a NAT ‘The slope of aluminum on the surface already at room temperature with oxygen to form an oxide layer to combine, is known. This propensity for oxide formation is at elevated temperatures, and thus during the melting too. 2.2 Fundamentals of Melt Treatment ‘The dagres of oxidation is mainly dependent on + The storage conditions and + The piece of material. and melting of: + Alloy composition, + melting temperature and + melting time and + from type of furnace, heating and melt /bath surface. Under the aluminum gas receptive is primarily the absorption of hydrogen (H2) understood. This arises in the implementation of liquid aluminum with water or water vapor. Water sources may Humidity: + use of the material, + the lining of the furnace, + of the crucible, + the fuel or the combustion air, + Melting of the preparations, + the tools and the surrounding alr. Other sources of hydrogen can be organic impurities. e.g. Lubricants, resulting from the mechanical processing of the material cycle is derived, In Figure 1 is the possible hydrogen content as a function of type of melting treatment and the condition presented. Figure 1 finale, Teoabecu Influence of the heating of { Pre melting and furnaces and ler lg nga ype type of alloy on the hydrogen | +t fay content ve geseele nea Group 1 : ready molt in pre treatment te ft i vastemolng ‘gash lr Dppeitieg- Cefn, lag 7 ope per Beg en, Le Ay 0S Group 2 ‘gavel Depplieg Gc leg AIMS Degassed and refined melts — ; during processing in a 7 permanent mold casting se Leigh ent je 189 Metall furnaces “Talis Tahing Hlihop Eng compldce Bre ‘ARG ENGINEERING HEXIGO SADE OV ‘andreas Kaela; 77272000. AI Between the various stages of melt treatment changes the hydrogen content of a melt, even when the temperature changes only slightly. 4s Figure 2 History of the hydrogen reduction at G-AISM 2CuNIT-racking from melting of pre including processing; Melt 1 Molten in a oil heated chimney chamber furnace. Melt 2 Molten in a Induction launder furnace; both metts filled in electrically heated resistance crucible furnaces, melt treatment done Evident from the images 1 & 2, that the influence on the Hydrogen solubility of aluminum alloys is very diverse, but by appropriate methods of treatment hydrogen also can be removed. The amount of aluminum in the maximum solvable hydrogen depends on the temperature (Fig. 8) and also on the alloy composition. We “o]] 1 ; I titi ‘ f st « 1 ‘vat + ey 0010) 500 at eo wD te Tengaetur Figure 3, Hydrogen solubiliy in solid and liquid aluminum as a function of temperature Despite all precautions, it can be repeatedly at the meeting of several adverse factors lead to a ‘metal in liquid stato has more gas than in the solid state at lower temperature can solve. As a result, then joined gas pores in casting microstructure on the wall thickness weaken the tightness of the castings into question and in each case to the Committee and rework lead, Talime-Training Motishop-Eng-compldos 36748 "AKG ENGINEERING MEXICO SADE CV "Andreas Kaela 7/12/20002 ANBIS Therefore, in the non-ferrous metal foundries melting diverse preparations and working procedures in order to avoid contamination and the harmful gases, especially from certain aluminum casting alloys, flush out. In the VDG MERKBLATT R-50 "heat-treatment agents for non-ferrous metals and alloys are some basic statements, which are briefly referenced. 2.3 Melt Treatment Funds according to VDG-Merkblatt R 50 2.3.1 Terms Lmettireatment Melt treatment is the sum of the measures to the quality of a certain melt composition influence, with disturbing effects away, but will also be favorable, These measures are physical and chemical regularities exploited, the melting of nonferrous metals are important. This definition includes both the use of heat treatment products - formerly also sometimes referred to as “enamel preparations’ means - one, as well as the use of appropriate devices and equipment. This may make the use of melt-treatment agents facilitate or promote in terms of impact, such as the use of bells, spears and blower equipment. it can also intends that, through the device itself (mainly physical regularities user) melt ‘treatment (creating a vacuum, shaking, Besch Allen, filters, stick out). 2 Molt treatment agents Melt-treatment agents are added to the melt, mainly as solids, but also fused (liquefied master patterns to influence) or applied as gaseous stale (purge gas). Tollme-Traiing Wallahop Eng-compidoe wee ‘AKG ENGINEERING MEXICO SADE GV ‘Andvoas Kalla; 7/12/2000a NAMA 2.3.2 Classification of mel-treatment agents The following schema is based either on purpose (lor example, as the action (eg, “oxidizing” detergents). lt auxiliary" medium), as well letersi [srnteoehnae I C men resco] rer enna] [ oe f 1 aoe oO, oes prove vera poe Far a Figure 4 Classification scheme for melt treatment moans in accordance with VOG-Factsheet R 50 Euston Tools ‘Melting aids are granular or powdery batch, mainly from inorganic substances, which are very reactive. The composition varies depending on the purpose; they may be one or more of the following tasks for intervention: - Flow education, to yield a feedstock to increase certain properties (flux, formerly also return winner, melting mentioned). + Reduction of the drain and slag, je mainly the reduction of unwanted oxidation (Covering; burn up preventer also mentioned earlier) - Education metal-poor, easily removable slag or dross's (De: Scabbing medium; formerly skimmer, scabies called separators). 2cleaners Cleaner (formerly known as Central refining, detergents or salts described) have the task of non- contamination of the melt to remove impurities, either by directly contacting the Funds or only after a chemical reaction that is called slagging. Cleaners are often grainy and crumbly. in nature and composition, they are similar to the melting aids and additives, which enable the cleaning process. Also shape parts (briquettes, tablets) are due to their ease of use (use with the good of charge) use. Especially deoxidizing funds have long been in metallic form as granules, blocks or wires are used. In the interest of the effect of the application is always the most intimate contact of the cleaning solution with the melt is required. ‘aline Tahning Nelishop-Engcompldoe ee "AKG ENGINEERING MEXICO SADE CV ‘Andreas Kaela; 771272000y AMM Cleaner is intended to cover unwanted alloying elements to remove or at least reduce the extent that they are no longer refevant. Removers are usually oxidizing chiorides or nature (eg of Cu-Al alloys or Na from AIMg alloys to Femove). Other implementations are possible, in the foundry operation, however, often problematic and therefore the more the stee! mill fu leave. ‘Of the components apart effective determinant similar remover in composition, performance and application form to the very detergents, 4.degasily Degasity are substances which are suitable in the melt dissolved gases primarily hydrogen - chemically or physically from the met off. Itis considered desirable effects often accompanying the Oxide content the melt (Rinse effect) decreased Comment on this question, both inert gases such as nitrogen or argon, as well as reactive gases such as chlorine, fluorine hydrocarbons or carbon dioxide. These gases are either in elemental form {individually or in mixture) initiated, of, where possible, also in the form of solids (compounds) is added, under the given conditions (melting temperature) of one or more of the gases released. For handling reasons (diving in the melt) are funding this type are mainly tablets or briquettes, including packaging in cans or tubes are in the trade. Often, the funds will also clean and slag: forming, less microstructure influencing components Distance 5 Microstructure influence funding In this group are all ways in which structure, ie in particular, the solidification behavior, the nature of the crystallization and the grain size influence, Two subgroups result from the alloy-related concerns of the practi - Refining substances are mainly in pure aluminum, AISI for certain alloys, as well as the Aballoy, which acts as the main alloying element Mg, Zn or Cu containing Important, But even at magnesium and copper alloys is a pellet refining practice or possible. As the principal is certain Refining element AISI phosphorus alloys used for other Al-alloys of titanium and boron The funds used are often means the titanium, zirconium, boron, phosphorus; sulfur, including elemental carbon, or in the form of reactive compounds, each in itself or in certain Combination. Also exothermic reaction promoters are often part of the funds, as granules, powders or shape parts mainly by immersion methods. Alternatively, but also metallic elements nucleation easily lumpy, even better than Master, packaged in portions (tubes, jars, packets), or In tho form of Blocks, wires, pellets can be used. - Processing means Found exclusively in AISI alloys with about 6 to 13% using slicon. They allow the sodium or strontium content of the melt which involves the formation of a normal fabric guaranteed. The nature of the compensating means is similar Retining substances the only one used here almost exclusively sodium and strontium. These are either metal - often packed (sodium) or a Master (Strontium), or - and this applies only to sodium -in the form Natrium giving salt mixtures added. ‘alimo-Tralning Malishop-Eng-compldoe Brae "AKG ENGINEERING HEXICO SADE GV ‘Andreas Kaloja; 71272000,AT You are the melt processing aids insofar as attributable to, as they do almost complete "disturbing effects away, favorable spawn". This may relate to such diverse elements such as phosphorus (for CuSn alloys, also known as “phosphor bronze") or manganese (to compensate {or iron influence in AISI alloys for sand and permanent mold casting) at al Alloying elements can be supplied to mel the element from either batch (also known as shape parts) suitable salts by reaction in the melt release, it can also be machined into the form itself is part of the batch or, in favorable dissolution behavior, or putely as a master offered, Sometimes there are transitions of alloy microstructure funds to influence resources and vice versa. Salloy 2.3.3 Environmental impact through the use of melt treatment products Molt treatment resources may be dependent on the nature and composition to human health, but this is usually only driven by non secure or improper use (ingestion of the product, inhalation of dust avoidable or non-derived, concentrated (Response) dampen. Extractors, where a heat treatment is cartied out are appropriate and are also required. Suitable for gases from smelting operations are upstream dust filers or (neutralizing) Scrubbers, especially when elemental chlorine or chloride giving funding will be used. The without and with application of heat treatment equipment resulting residues such as slag’s, ashes of drosses are due to their precious metal content and smelting works for an operational matter. Itis thus to economic goods in terms of waste disposal law. As such they should be up to deliver to a recycling company dry and leaching by water stored. Due to their low metal content are no longer usable residue if necessary with lime water must be ‘completely neutralized before they are ordered to a landiil can be accommodated. Residues, the soluble heavy metal salts such as zinc chloride or manganese chloride, betong to the special landfill 2.4 Degassing systoms for aluminum alloys Most of today’s melting-treatment preparations and simultaneously fulfil the task of removal ~ Both gas - As well as from non-inclusions, Motallic impurities are in the foundry virtually no, or at least not entirely from the melt to remove. The agreement should be subject to the treatment requirement as just before and alter casting ‘opportunity in the ladle or in the crucible made. Too early treatment can be prepared by various extemal influences, especially by retlling into another container, again lose their effect. Recommendable may be electrically heated ladies. For the examination of the gas content of the remaining untreated melt are different procedures available, which also help the effectiveness of a Degassing treatment can be controlled. On the measures for the quality of a melt will later detail For the cleaning and degassing of aluminum melts are basically 8 cases in question: + the ,standing / waiting time* + Gas- Rinse system + Low pressure treatment Taline-Tralning Melishop-Eng-compldos———~SC«MOTAS "ARG ENGINEERING MEXICO SA DE GV ‘andreas Kaela; 7/12/2000i NAT It is easy to understand that in prolonged melt standing melting non-metallic impu parlicularly oxides, depending on the densily and rise upward into the dross, or at the bottom of the melt to accumulate. The latter would not be desirable, since they are then not readily removed would. However, experiance has shown that oxides of Al and Mg, although they specifically slightly heavier than the aluminium smelting always rise to the top layer and the reinforcing scabies. Obviously, they are equipped with the finest hydrogen bubbles are tainted and therefore specific lighter. ‘The hydrogen solubility decreases, as shown in Figure 3, with decreasing temperature. Furthermore, there is a balance between the hydrogen content of the melt and the moisture content of the surrounding air. By approaching stick out of the hydrogen content of the met this equilibtium state. So it is advantageous that “melt standing” under low temperature and preferably under a dry atmosphere made possible, Hydrogen bubbles can melt in a pure form is very difficult. Oxide particle can act as a bubble germ. We recognize that between hydrogen content and fine ground / spread Oxide particle a close relationship. 2.4.1 Melt standing / waiting time ‘As Figure § shows, the degassing by stick out extremely slow. Therefore, the practical importance of melt standing low on, = Grenzwert: flx,t,2) Wasserstoffgehalt —» Verhiltnisse + Matalltempecatur 2 Metallzusammensetzung o Behandlungsdauer —» Figure 5 schematic representation of various degassing systems Moreover, in the best case, only the equilibrium hydrogen content are achieved by the bath temperature and the moisture content of the environment depends. 2.4.2 Gas-tinse system ‘When flushing with gases are, in principle, the same laws as the stick out. ae "AKG ENGINEERING MEXICO SADE GV ‘Androas Kola; 7/2/2000i NAIA The reaction takes place not on the outer surface of the melt, but in an “inner" surface, caused by rising gas bubbles is formed. Instead of the humidity of the surrounding air occurs, however, the rinse gases, which is practically equal to zero. Furthermore, depending on the fineness of the surface area more rinse gas bubbles and practically the entire volume of the melt surface with this comes into contact. Through the above-mentioned effect of the y" of gas bubbles in non-contamination ‘occurs is also an improved cleaning effect. Because the deposited bubbles increase the buoyancy of the particulate pollution and help them through the “elevator effect® up to the bath surface, trom where they are relatively easy to remove. Nitrogen and argon as rinse gas are environmentally neutral and affect the chemical composition of the melt not. The effect depends crucially on the distribution of fine bubbles from, Figure 6 orders of Gas exhaust openings in the induction pipes ‘A turther development, the rotating nozzle of the gas rinse system. Since the mid-80s are increasingly appropriate device for use in foundries used (Figure 7 rotor degassing, "Impeller". This technology is currently expected to represent an optimum. It is essential that the crucible diameter, rotor diameter and pressure of the rinse gases ate aligned so that the metat surface remains flat and no vortex formation occurs, the mixing of the dross layer containing the metal cause. Figute 7 device for rotor degassing ‘Talime-Talning Walishop-Eng-compldoe ares "ARG ENGINEERING MEXICO SADE GV ‘andreas Kaela; 7/12/2009i NIA For small quantities of motal has proven itself to be the veatment of the metal salts or with Nitrogen separating tablets. They contain mostly calcium cyanamide (calcium), which is at the temperature of the melt in the release of nitrogen decomposed, For the Gas rinse with chlorine and chlorine mixtures are, in principle, the same regularities as {or flushing with inert gases. However occurs at elevated Magnesium burn up and a treatment already carried out to refine the casting microstructure (finishing) by the Chlorine treatment nullified. Otherwise, the experience shows that a chlorine treatment - Especially in relation to the removal of oxide impurities - a Inert gas treatment is superior. At this point was often made to the experience noted that once a largely solid non metallic impurities liberated melt hardly be re-recording tends hydrogen. Widespread is stil the use cchloring separating salts and tablets based on hexachloroethane C2CI6. ‘The main disadvantage of chlorine is its toxicity. Appropriate washes exhaust must be provided. Moreover, the labour force environmental rules! 2.4.3 Low Pressure Treatment ‘The long-known principle of negative pressure or Vacuum degassing, which include smelters, foundries large technically is applied has been since the late'70s in the form of foundries Introduced (Figure 8). ‘When lowering the pressure above of an aluminium melt between the melt the dissolved gases ‘get out easier. During advancement of the small vesicles are also in the melt floating Oxide skins upwards and are easier removable. By avoiding aggressive cleaning gases arise from the vacuum further advantages in handling, The main advantages of the procedure are: - Environmental friendliness - No Mg-and Sr-burnout, Low-Na melts grafted burn-in, - Avoidance of corrosion damage to buildings and facilites. Due to the strong pressure reduction is achieved, the dissolved hydrogen quickly escapes from the metal. However, this should be noted that this low pressure only on the metal surface is. By static pressure is the pressure as 10 cm below the bath surface again later. itis therefore hecessary, to mix the bath so that any subset comes in contact with the bath surface. Since the temperature differences created by flow (convection) is usually not sulficient, itis usually as in Figure 8 shows a certain amount of inert gas through a “Rinse lance” during the treatment period initiated. Treatment times between 5 to 30 min can be achieved under favourable conditions. @/%_______ AKG ENGINEERING HEXICO SADE CVi. Figure 8 Warrant for Low pressure degassing ina container. 4 Award with insulation 2 base plate 3 Biower- / Rinse lance with rinso system 4 lifting 5 Sight glass with orice 6 Vacuum Connection. 7 crucible with melt 8 Resistance Heating 91 ‘A procedure, in which furnace gasses by negative pressure go through the porous crucible wall by tho molt to be sucked, is patented. The furnaces gasses but are on the path of least resistance above the metal bath, the crucible wall pass, so that the practical effect of the usual low pressure degassing system is identical. Due to the rising hydrogen bubbles are also used in Vacuum degassing a Gas rinse effect in terms of oxidic impurities is exercised. 2.5 Cleaning Procedure The effect of enamel preparations Is aimed at both, impurities transported to the bath surface (Flotation's effect), as well as to carry out chemical reactions, Essential for the cleaning effect is the intense mixing of the molten salts with the cleaning. There are also facilities available for the tion of salts with Inert gas flow injection (inject). For thin-walled or heavily contaminated material, the use of cleaning salt often simultaneously with the solid metal in order to better oxide can bind to direct heating or to reduce the burn. In crucible furnaces should be noted that the graphite crucible of the salts can be, this can lead to a shortening of the pot stand times. For magnesium alloys recommends the use of cleansing salts which contain MgCl2, in order to avoid Magnesium burnout. Because of the strong rising water (hygroscopic) properties of MgCI2 is here, as with any other melt treatment preparations, because of the tisk of moisture absorpti with special care to ensure dry storage. Scrub salts have the function of interfacial intera scabies. Oxides and other solid impurities melt can be removed by filtering the alloy. The possibilities for arrangement of filters are varied, is mentioned here only in the melting pot with attached fiter used fiter insert. As filter material basalt is suitable, others lke Sinterkorund, even in fibreglass fabrie or cloth-bag form are also suitable. With good success has introduced a ceramic filter, which is characterized by a very high pore volume concerned. It is in standard panels and adapted formats. Pass filtering; however, are suitable mainly for the flow of large quantities of metal (eg casting). In through a clean separation of metal and 'AKG ENGINEERING MEXICO SA DE CV ‘Andreas Kaleja; 7/2/2009 ‘Tolime-Tralning Melishop-Eng-compl doeAGA 2.6 pellet refining 2.6.1 Basics In a molten metal to move the metal atoms due to their high energy content relative to each other freely. When cooling, the energy content of the melt from. The intensity of thermal vibrations of the individual metal atoms decreases with decreasing temperature as well. This will reduce the distances of the individual metal atoms, and their altraction forces are greater. The task of cleaning procedures and preparations (as is already written in the VDG-Facisheet R 50 above) is the removal of non metallic impurities (oxides, form chemical and lubricant residues, etc.). Ii a typical fuel temperature (solidification temperature) goes further in energy output from the pure liquid metal inthe solid (crystalline) state. The onset of crystallization is small crystalization centers, the germs, provided, in which more energy-poor nuclear plants so as to build the metal crystal. To each germ grows in this way, a uniformly oriented crystalline field under “erosion of the residual melt.” This crystal field is also called crystallites or KORN. many germs effectively, it also begins the crystal growth in many places and the inner structure of the solidified casting is determined by many small grains formed. Italso says: The casting has a fine-grained microstructure. The fine-grained microstructure caused desirable properties in the ca: and is therefore through appropriate measures and tested specifically sought. 2.6.2 Refining supplies The usual trade Refining supply are salt tablets or capsules for use in the foundry and are prepared for a chemical reaction in the melt as a foreign germ, ‘The best pellet refining is achieved with the two double fluorides potassium titanium fluoride and potassium Bor fluoride. Both salts are available in tablets; a variant has a heat losing reaction. Both salts react in the melt and form extremely small TIB2 germs. After about 20 minutes this sounds excellent germ effect and after 40 minutes, the pellet refining repeated. For sand, this is inrelevant, since the melt is not standing. Adding quantities from 0.1% are normal. The needed ‘amount is to introduce by dipping into the melt with a dry finely perforated bell. ‘A much longer pellet refining is achieved with TiB2 from master. The most common AL-Ti-B master contains 5% titanium and 1% boron, the TiB2 germs from the master are much coarser, {go together easily and Seiger from. Boron is well known other elements, such as titanium, vanadium from aluminium smelting. Therefore, it is cheaper in the long melting, as in Low pressure casting machines, AlMaster with 5% Ti and 0.2% B to use. For AISi casting alloys, the eutectic silicon in an alloy in the forms (modifications) granular, lamellar and refined occur (Bild9) Talime-Tralning Melishop-Eng-compldoc we "AKG ENGINEERING MEXICO SADE GV “Andons Kelela; 7/2/2008Figure 9 Microstructure training granular, lamellar and refined at the same G-AISi alloys Grainy it because of the rough, wrinkled training, strong breaks in the soft ground mass. The material is less ductile (ductile). Lamellar eutectic silicon results although a ductile material, but because of the spongy Congeaiing dificult to shed and has therefore a large shrinkage cavity. ‘The refined alloy results in a ductile material and is excellent cast ability Granular structure can be determined by sodium or strontium addition in the refined moditication convert, Lamelar structure on the other hand, can be determined by sodium or strontium addition is not 100 -% ig in the refined modification on lead, then it is a mixed pattern between the two species. The mixing pattem is the founder of micro porosity and cavitations melting major problems. 2.7 Melting and treatment process monitoring {In order to produce good castings is the quality control of the melt and their entire deployment process before casting essential The tests of the melt before casting should relate to: + The chemical composition, - The presence of impurities (oxides, gases), - The treatment of the condition relating to the melt degassing, pellet refining, refining In the VDG-facisheet $ 601 ‘assessment of the quality of Aluminium alloy melts 11 are basic ‘connections and test methods listed. re "ARG ENGINEERING MEXICO SA DE GV ‘Andreas Koloja; 7/2/2000ANITA CHAPTER D The high pressure Die casting product The production of impeccable high pressure die casting products requires a precise control and monitoring of production conditions and the manufacturing process. Here are several causes may lead to casting mistakes whose elimination requires process engineering knowledge. 1. Quality nature AA high pressure die casting product met in general much higher qualiy’s than a part produced from the same material in sand mold casting. The pressure casting is certainly a viable method for the manufacture of finished products, which only requires low post. 2, Casting / Part errors and their causes The quality of die casting parts undor the influence of various factors and influences, which also interact with each other may exist. An overview of the most common error symptoms and their ‘causes is the following pictures below. ‘CASTING ERRORS AND THERE SOURCES eS a oo i 5 i revenue i, 4 2 ita oiiilbdeg : fuifned ¢ if Ha cnmsiratanen | sedidedi Sage geERGty i feeaaeee eee Peibad ie seagededslsa: qiiiii a aseae hes sess 55555 5 Bi 2 eT | 7 | A CY 4 =| = D 7 at 7 : 1 famous = arab ERE Tali Tang eshap Eng complaoe aT ARG ENGINEERING WERIEO BA DEC ‘angreas Kaleje; 7/2/2000Imago 1) Bubble inclusion () in ne imayo 2) Ca of hkwaod air poocets in tho ara of thin ald bass OC casing part an aluminium high pressure casting part Image 3) Sample of a broken aluminium de casting part wilh poraus slructure due to inadequate sharing mutigher {eamplo 1 at 500 °C outsourced) 4) Die casting part with rough surfaco rogaraing of 5), Marks ofthe elector pins ata high song eracks in the mould ron prossure die casting part ‘Talim Talring Nelishop- Eng-compldoe are ‘AKG ENGINEERING MEXICO SA DE GV ‘Anoreas Katoja 74272008‘ PRR casing microstuctore ofthe alloy GO-AIS12 (Cu) 7), Cold tow wth overlapping wih Sage grey ares of ph au casing “Temperature (V = 100 Telime-Treining-Melishop-Eng-compldoe ere "AKG ENGINEERING MEXICO SADE OV ‘Andveas Kaela; 7/12/2008