鋁和鋁合金變成finished鋁產品和半成品產品通過融化和鑄造。在熔化和鑄造過程中，由於氧化，煉油，清除爐渣的去除等，將發生各種程度的損失，從而導致不可恢複的金屬損失和鋁渣。
The general calculation formula of casting loss is: (the amount of primary aluminum – the number of finished products) ÷ the amount of primary aluminum × 100%, the higher the casting loss, the less the finished product, so how to effectively reduce the casting loss is very important.
Causes of aluminum alloy casting damage
鑄造損傷的主要外部表現可以分為兩個部分：一種是純鋁灰的形式，另一種是大塊的鋁，有缺陷的鋁和鋁渣的形式。其中，不可回收的純淨鋁灰約占鑄造損失的90％，其他因素約占10％。其他因素主要是由大型鋁合金和有缺陷的鋁合金以及鋁合金灰分中鋁合金的含量引起的。因此，內部鑄造損害的主要原因是氧化燃燒損失，二次燃燒損失，例如鋁和鋁灰。
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①液體鋁溫度；
②熔融鋁和氧的接觸強度；
③鋁渣中的鋁含量；
④The molten aluminum brought out by slag skimming;
⑤ The amount of defective aluminum and bulk aluminum;
⑥Other losses.
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1. Control the temperature of liquid aluminum.
The melting point of aluminum is 660°C. Generally speaking, the casting temperature of primary aluminum is controlled at about 730°C or even lower, while the aluminum alloy has better fluidity and the corresponding casting temperature is lower than that of primary aluminum, about 710°C-730°C. The temperature of molten aluminum is effectively reduced to the corresponding casting temperature, which can reduce the huge influence of temperature on casting loss.
2.降低熔融鋁和空氣的接觸強度。
（1）減少液體鋁和氧氣之間的接觸時間。在滿足生產需求的情況下，爐中的液體鋁應盡快將其變成成品。最好在值班時生產出值得的成分，不要讓液體鋁在爐子中持續太久。合理地安排鑄造設備，並盡可能縮短洗滌的長度。，為了減少空氣中液體鋁的暴露時間，同時，可以將鋁矽酸鹽絕緣板添加到洗衣的上部，這不僅具有一定的絕緣效應，而且還會減少中的氧氣含量洗錢。
（2）控製液體鋁的攪拌模式。
與爐門打開的攪拌不僅會在液位上引起巨大的波動，並增加與氧氣的接觸區域，而且還會增加爐中的氧氣含量，加速化學反應並增加燃燒損失。電磁攪拌可以在封閉狀態下進行，並且液位波動很小，這有效地避免了相應的缺點。同時，它還可以減少進入爐子的空氣中的水分，並降低液體鋁向氫的吸收概率。
3. Control the height of the bubble blowing.
The general refining method is to manually sprinkle the refining agent into the furnace, and then perform stirring and refining. However, for some alloy production, nitrogen-blowing refining is required (the refining time is longer, up to about 30 minutes), and there must be a certain blowing height. , which drives the huge fluctuation of liquid aluminum, so it is best to adjust the nitrogen pressure and control the blowing height to 10-15mm.
4. Correctly select and use the refining agent to fully separate the slag and aluminum.
In the smelting process of aluminum and aluminum alloys, in addition to their inclusions, aluminum can easily form alumina or sub-alumina with oxygen, resulting in a layer of scum on the surface of the molten aluminum.
除了使用通量工廠產生的通量外，還最好根據燃料的鋁合金的組成來調整通量成分的比例。同時，嚴格控製了精煉過程條件，例如通量的量，通量和熔體之間的接觸時間，接觸區域，攪拌狀態和溫度。
5. Effectively deal with the aluminum slag produced.
鋁渣是熔融和鑄造過程中必不可少的一部分。盡管采取了相關的措施，但將取出一定比例的金屬鋁，需要有效治療。進行篩選以有效恢複部分鋁豆。
6.嚴格控製清除爐渣的質量，以防止液體鋁被帶出。
The existing slag scraping operation uses a large rake to scrape the aluminum slag out of the door of the furnace. During this operation, in addition to requiring personnel to operate carefully, try not to bring out the molten aluminum. At the same time, the design of the large rake also needs to be carefully considered. Several rows of small round holes are opened on the surface of the rake so that the liquid aluminum contained in the aluminum slag can flow into the furnace, otherwise, too much liquid aluminum will be brought out and returned to the furnace again, which will cause burning damage.
7. Reduce the amount of defective aluminum and bulk aluminum.
In the production process, operate in strict accordance with the process requirements to ensure that one furnace is produced and one furnace is qualified. Especially in the process of producing ordinary aluminum, try to avoid the generation of defective aluminum such as flash, burr, corrugation, and weight inconsistency. Before the end, push the liquid aluminum in the launder as much as possible into the mold to form a qualified product to reduce the amount of large aluminum.
Summary
Although casting loss is inevitable in the melting and casting process, controlling the temperature of the molten aluminum, reducing the contact strength between the molten aluminum and the air, controlling the aluminum content in the aluminum ash, and reducing the amount of defective aluminum, the casting loss in the melting and casting process can be effectively reduced. , will produce significant effects, and will certainly bring considerable economic benefits to the enterprise.
