AA5182大型Al-Mg合金铸锭熔铸过程研究
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摘要
作者根据生产现场实际铸造情况,以AA5182大型Al-Mg合金铸锭作为研究对象,采用LHC铸造工艺,对比研究了传统直冷铸造(DC)工艺与低液位铸造(LHC)工艺对铸锭产品质量的影响。探讨了如何优化铝液除氢工艺,以及如何克服铸锭热裂、漏铝缺陷的方法。并通过实际生产应用,创造性地提出了通过优化冷却强度和铸造速度之间的匹配性,降低铸锭表面Mg偏析层厚度的方案。在此基础上,提出了达到低液位铸造工艺的条件。
与常规尺寸的铸锭相比,大型Al-Mg合金熔炼铸造时存在的难点在于,由于铸锭尺寸规格的增加,导致熔炼过程中熔池深度的增加,铝液搅拌过程困难,熔池内化学成分不均匀。铸造时铸锭轧制面和端面冷却强度不均匀,产生铸造缺陷。本文采用先进的熔炼铸造工艺,克服熔铸过程的难点,优化熔铸过程。获得了合格大型铸锭,满足了生产需求。
通过对铝液中氢含量以及氧化夹杂物含量的控制,结合Al-Mg合金铝液中Mg含量较高的特点,特别是Mg含量高对铝液氢含量的影响,重点研究了铝液净化过程的工艺特点及方法。首先采用透气塞在保温炉内进行除氢,然后采用铝液精炼系统(LARS),通过对精炼气体Ar预热方式的优化,降低由于气泡热胀冷缩而带来的气泡体积膨胀程度,达到提高除氢效果的目的。另外,通过改进精炼箱箱体几何形状的设计,使精炼气体气泡膨胀程度与箱体截面积增大程度相互匹配,防止气泡相互融合到一起。这样能够提高除氢效果,对于AA5182合金铝液,当入口铝液氢含量小于0.300ml/100g的情况下,除氢效率能够达到50%—60%,铝液中的氢含量控制在0.150ml/100g以下。
针对铝液中含有的氧化夹杂物,本文采用陶瓷过滤(CFF)系统,采取两片过滤片平行放置的方式,在提高铝液通过量的同时,提高过滤效果。通过加大助燃空气的流量,改善过滤片的预热效果。使用50ppi过滤片的条件下,对于AA5182合金铝液中20μm以上的氧化夹杂物,过滤效率达到70%以上,有效满足了大型Al-Mg合金铸锭的质量要求。
传统DC铸造工艺条件下,对于大型Al-Mg合金铸锭,Mg偏析层厚度达到5mm左右,增加了铸锭铣削量。本文通过优化铸锭冷却强度和铸造速度,使二者相互匹配,同时在结晶器内表面安装石墨内衬,这样能够在铸造过程中达到低液位铸造的条件,降低铸锭表面的Mg偏析层厚度。采用LHC铸造的条件下,铸锭表面Mg偏析层厚度控制在1.5mm左右,比传统DC铸造生产的铸锭表面Mg偏析层厚度降低60%-70%,优化了铸锭产品质量,降低铸锭表面的铣削量和生产成本。
通过优化LHC铸造工艺条件,包括铝液液位高度、铝液温度、冷却水流量、铸造速度等参数,本文总结了LHC铸造的优点,特别是对于减少相关铸造缺陷,降低Mg偏析层厚度等方面的作用。在此基础上,本文对相关铸造缺陷,包括热裂、漏铝、冷隔等缺陷进行了研究。通过优化冷却方式,并加强晶粒细化效果,将铸造速度控制在工艺要求的范围,能够有效改善铸锭缺陷,提高铸锭产品质量。
本文对AA5182大型Al-Mg合金铸锭的熔铸过程,包括合金成分的保证、熔炼铝液的温度以及均匀性、铝液除氢工艺、氧化夹杂物的净化工艺、铸锭质量优化、以及铸造时出现的Mg偏析、热裂、漏铝、冷隔等方面的缺陷进行了详细论述。对于Mg含量高达4.0%-5.0%的AA5182大型Al-Mg合金铸锭的熔铸工艺,进行了有针对性的论述,在实际铸造过程中,具有重要的指导意义。
In the present paper,according to the casting practice,the AA5182 Al-Mg alloy large size ingots were investigated by means of the low metal head casting.The influence of the conventional direct chill(DC) casting and the low metal head casting (LHC) to the ingot quality was discussed.The hydrogen degassing process in the liquid aluminum,the hot crack and the bleed out of the ingot have been discussed.By the means of matching the water cooling rate and the casting speed during the casting practice,Mg segregation layer thickness could be reduced.Based on all above,how to achieve the low metal head casting condition is concluded during the investigation.
The difficulty of the large ingot was clarified by comparing the large ingot with the small size ingot.Because the size is large,the liquid metal bath is much deeper than the normal melting process.Then the stirring of the liquid metal is more difficult than before and the chemistry uniformity of the liquid metal isn't as good as the normal process.During the casting process,the cooling water on the ingot rolling face and the ingot end face are different.This results in the casting defects.The advanced melting and casting process are investigated to solve the problem and optimize the whole process.The large size ingots quality is good and this meets the requirement of the process.
By the control of hydrogen content and dross content in the liquid aluminum, together with the influence of the high Mg content to the hydrogen level in the liquid aluminum,the hydrogen degassing process has been discussed.First of all,the porous plugs are used in the holding furnace for hydrogen degassing.Then,with the optimization of the Ar preheating in the liquid aluminum refining system(LARS),the bubble expansion for high temperature of the liquid metal is reduced and the degassing process is optimized.In addition,by the design of the degasser vessel shape, the section of the vessel matches with the bubble expansion.So the bubbles wouldn't be merged with each other.The degassing efficiency could be improved,for AA5182 alloy liquid aluminum,when the entrance hydrogen content is lower than 0.300ml/100g,the hydrogen efficiency could be 50%—60%.And the hydrogen level in the liquid aluminum could be lower than 0.150ml/100g,this meets the requirement of the ingot quality.
For the inclusion in the liquid aluminum,the ceramic foam filter(CFF) system is applied.With two tiles installed in the filter bowl side by side,the liquid aluminum flow rate and the filtration efficiency could be improved.With the help of increasing the combustion air flow rate,the preheat process is optimized.At the same time,with 50ppi filter tile,for the inclusion size of more than 20 microns,the filtration efficiency could be higher than 70%.
During the conventional DC casting process,Mg segregation layer thickness is about 5mm in the large size of ingot.The Mg segregation layer affects the ingot quality,the scalping thickness should be more than usual.By the optimization of the water cooling rate and the casting speed,so that they are matched with each other.At the same time the graphite liner is installed inside the casting mold,then the low metal head casting condition is achieved,the Mg segregation layer thickness will be reduced to about 1.5mm.The LHC casting ingot Mg segregation layer thickness is 60%-70% less than the DC casting ingot.The ingot quality is improved and the scalping thickness is reduced.
By the optimization of the LHC casting process parameters,such as the liquid aluminum level,the temperature of the liquid metal,the cooling water flow rate and the casting speed,the profit of the LHC casting process is investigated.Especially the effect of the LHC casting process to decrease the relative defects and decrease the Mg segregation layer thickness is highlighted.The relative ingot defects during the casting process are investigated,such as the hot crack,the bleed over,the cold folding, and so on.By the optimization of the cooling process,the improvement of the grain refining process,and the suitable casting speed,the defects could be reduced or avoided.Then the quality of the ingot could be improved.
The whole melting and casting process of the large AA5182 alloy ingot, including the chemistry of the alloy,the melting temperature difference,the liquid aluminum degassing process,the filtration,the optimization of the ingot quality,and the defects of the Mg segregation,the hot crack,the bleed over,and the cold fold have been highlighted.The AA5182 ingots with high Mg content of 4.0%-5.0%are investigated.Especially the specialty during the melting and casting process is discussed in detail.So this thesis will be the guidance to the practice of the AA5182 alloy large ingot.
与常规尺寸的铸锭相比,大型Al-Mg合金熔炼铸造时存在的难点在于,由于铸锭尺寸规格的增加,导致熔炼过程中熔池深度的增加,铝液搅拌过程困难,熔池内化学成分不均匀。铸造时铸锭轧制面和端面冷却强度不均匀,产生铸造缺陷。本文采用先进的熔炼铸造工艺,克服熔铸过程的难点,优化熔铸过程。获得了合格大型铸锭,满足了生产需求。
通过对铝液中氢含量以及氧化夹杂物含量的控制,结合Al-Mg合金铝液中Mg含量较高的特点,特别是Mg含量高对铝液氢含量的影响,重点研究了铝液净化过程的工艺特点及方法。首先采用透气塞在保温炉内进行除氢,然后采用铝液精炼系统(LARS),通过对精炼气体Ar预热方式的优化,降低由于气泡热胀冷缩而带来的气泡体积膨胀程度,达到提高除氢效果的目的。另外,通过改进精炼箱箱体几何形状的设计,使精炼气体气泡膨胀程度与箱体截面积增大程度相互匹配,防止气泡相互融合到一起。这样能够提高除氢效果,对于AA5182合金铝液,当入口铝液氢含量小于0.300ml/100g的情况下,除氢效率能够达到50%—60%,铝液中的氢含量控制在0.150ml/100g以下。
针对铝液中含有的氧化夹杂物,本文采用陶瓷过滤(CFF)系统,采取两片过滤片平行放置的方式,在提高铝液通过量的同时,提高过滤效果。通过加大助燃空气的流量,改善过滤片的预热效果。使用50ppi过滤片的条件下,对于AA5182合金铝液中20μm以上的氧化夹杂物,过滤效率达到70%以上,有效满足了大型Al-Mg合金铸锭的质量要求。
传统DC铸造工艺条件下,对于大型Al-Mg合金铸锭,Mg偏析层厚度达到5mm左右,增加了铸锭铣削量。本文通过优化铸锭冷却强度和铸造速度,使二者相互匹配,同时在结晶器内表面安装石墨内衬,这样能够在铸造过程中达到低液位铸造的条件,降低铸锭表面的Mg偏析层厚度。采用LHC铸造的条件下,铸锭表面Mg偏析层厚度控制在1.5mm左右,比传统DC铸造生产的铸锭表面Mg偏析层厚度降低60%-70%,优化了铸锭产品质量,降低铸锭表面的铣削量和生产成本。
通过优化LHC铸造工艺条件,包括铝液液位高度、铝液温度、冷却水流量、铸造速度等参数,本文总结了LHC铸造的优点,特别是对于减少相关铸造缺陷,降低Mg偏析层厚度等方面的作用。在此基础上,本文对相关铸造缺陷,包括热裂、漏铝、冷隔等缺陷进行了研究。通过优化冷却方式,并加强晶粒细化效果,将铸造速度控制在工艺要求的范围,能够有效改善铸锭缺陷,提高铸锭产品质量。
本文对AA5182大型Al-Mg合金铸锭的熔铸过程,包括合金成分的保证、熔炼铝液的温度以及均匀性、铝液除氢工艺、氧化夹杂物的净化工艺、铸锭质量优化、以及铸造时出现的Mg偏析、热裂、漏铝、冷隔等方面的缺陷进行了详细论述。对于Mg含量高达4.0%-5.0%的AA5182大型Al-Mg合金铸锭的熔铸工艺,进行了有针对性的论述,在实际铸造过程中,具有重要的指导意义。
In the present paper,according to the casting practice,the AA5182 Al-Mg alloy large size ingots were investigated by means of the low metal head casting.The influence of the conventional direct chill(DC) casting and the low metal head casting (LHC) to the ingot quality was discussed.The hydrogen degassing process in the liquid aluminum,the hot crack and the bleed out of the ingot have been discussed.By the means of matching the water cooling rate and the casting speed during the casting practice,Mg segregation layer thickness could be reduced.Based on all above,how to achieve the low metal head casting condition is concluded during the investigation.
The difficulty of the large ingot was clarified by comparing the large ingot with the small size ingot.Because the size is large,the liquid metal bath is much deeper than the normal melting process.Then the stirring of the liquid metal is more difficult than before and the chemistry uniformity of the liquid metal isn't as good as the normal process.During the casting process,the cooling water on the ingot rolling face and the ingot end face are different.This results in the casting defects.The advanced melting and casting process are investigated to solve the problem and optimize the whole process.The large size ingots quality is good and this meets the requirement of the process.
By the control of hydrogen content and dross content in the liquid aluminum, together with the influence of the high Mg content to the hydrogen level in the liquid aluminum,the hydrogen degassing process has been discussed.First of all,the porous plugs are used in the holding furnace for hydrogen degassing.Then,with the optimization of the Ar preheating in the liquid aluminum refining system(LARS),the bubble expansion for high temperature of the liquid metal is reduced and the degassing process is optimized.In addition,by the design of the degasser vessel shape, the section of the vessel matches with the bubble expansion.So the bubbles wouldn't be merged with each other.The degassing efficiency could be improved,for AA5182 alloy liquid aluminum,when the entrance hydrogen content is lower than 0.300ml/100g,the hydrogen efficiency could be 50%—60%.And the hydrogen level in the liquid aluminum could be lower than 0.150ml/100g,this meets the requirement of the ingot quality.
For the inclusion in the liquid aluminum,the ceramic foam filter(CFF) system is applied.With two tiles installed in the filter bowl side by side,the liquid aluminum flow rate and the filtration efficiency could be improved.With the help of increasing the combustion air flow rate,the preheat process is optimized.At the same time,with 50ppi filter tile,for the inclusion size of more than 20 microns,the filtration efficiency could be higher than 70%.
During the conventional DC casting process,Mg segregation layer thickness is about 5mm in the large size of ingot.The Mg segregation layer affects the ingot quality,the scalping thickness should be more than usual.By the optimization of the water cooling rate and the casting speed,so that they are matched with each other.At the same time the graphite liner is installed inside the casting mold,then the low metal head casting condition is achieved,the Mg segregation layer thickness will be reduced to about 1.5mm.The LHC casting ingot Mg segregation layer thickness is 60%-70% less than the DC casting ingot.The ingot quality is improved and the scalping thickness is reduced.
By the optimization of the LHC casting process parameters,such as the liquid aluminum level,the temperature of the liquid metal,the cooling water flow rate and the casting speed,the profit of the LHC casting process is investigated.Especially the effect of the LHC casting process to decrease the relative defects and decrease the Mg segregation layer thickness is highlighted.The relative ingot defects during the casting process are investigated,such as the hot crack,the bleed over,the cold folding, and so on.By the optimization of the cooling process,the improvement of the grain refining process,and the suitable casting speed,the defects could be reduced or avoided.Then the quality of the ingot could be improved.
The whole melting and casting process of the large AA5182 alloy ingot, including the chemistry of the alloy,the melting temperature difference,the liquid aluminum degassing process,the filtration,the optimization of the ingot quality,and the defects of the Mg segregation,the hot crack,the bleed over,and the cold fold have been highlighted.The AA5182 ingots with high Mg content of 4.0%-5.0%are investigated.Especially the specialty during the melting and casting process is discussed in detail.So this thesis will be the guidance to the practice of the AA5182 alloy large ingot.
引文
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