Common Faults and Improvement Measures for Aluminum Rod Horizontal Continuous Casting

Release time:

Oct 26,2023

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The process of aluminum rod horizontal continuous casting does not require a tall factory building. It has the characteristics of simple equipment, low investment, and quick results. During casting, the aluminum rod is directly pulled out of the furnace, and the melt has no casting drop and no contact with the atmosphere. This avoids oxidation, slagging, and air absorption, and the quality of the casting rod is guaranteed.

During the process of aluminum rod horizontal continuous casting, phenomena such as breakage and leakage of aluminum rods often occur due to improper process measures and operations, resulting in interruption of the production process.

This article will start from the principle of the process of aluminum rod horizontal continuous casting and combine it with the actual production to analyze the phenomena such as breakage, leakage, and failure to pull out the rod during the production process and propose possible improvement measures.

Luoyang HTGP aluminum rod horizontal continuous casting

Aluminum Rod Horizontal Continuous Casting Process

The metal melt in the aluminum melting furnace enters the crystallizer through the liquid flow channel, crystallizes, grows, becomes solid in the crystallizer, and is pulled out from the outlet of the crystallizer. The crystallizer is made of ordinary copper and has a lubrication system inside. The melt is cooled and solidified in the crystallizer to obtain an aluminum rod with a dense structure. From the melting furnace to the crystallizer outlet, the molten aluminum undergoes a series of complex processes such as nucleation, grain growth, and metal solidification to become solid.

Three Basic Conditions

In order to ensure that the continuous casting process can continue, at least three basic conditions must be met:

First, molten metal can be continuously supplied;

Second, the metal solidifies at a certain speed in a certain area of the crystallizer, and the metal is pulled out at a corresponding speed;

Third, the heat exchange is balanced, that is, the heat released by the solidification of the liquid metal is equal to the sum of the heat taken away by the cooling water, the heat dissipated in other ways, and the residual heat of the aluminum rod after pulling out the crystallizer.

The first two conditions are indispensable, while the third condition can be adjusted by itself within a certain range by moving the solidification area to establish a new balance. In order to meet these three conditions, a series of process measures must be taken in practice:

For example, increase the melt temperature in the furnace and shorten the solid channel, so that the liquid in the liquid phase area has sufficient superheat to ensure the fluidity of the melt;

Use a casting speed that is compatible with the solidification speed to ensure continuous metal solidification in a certain area of the crystallizer;

Two times cooling is used to ensure that the melt solidifies at a certain speed and maintains continuous thermal balance.

Analysis of Common Faults in Aluminum Rod Horizontal Continuous Casting

Horizontal continuous casting of aluminum rods has the characteristic that the crystallization front is formed preferentially on the lower side of the ingot. In order to ensure the continuous progress of the continuous casting process, it is necessary to prevent the crystallization front from extending into the liquid flow channel. For this purpose, there must be sufficient temperature gradients in the liquid phase, solidification zone, and solid phase zone. Because the width of the solidification zone of the alloy ingot only depends on the crystallization temperature range of the alloy and the temperature gradient of the longitudinal section of the ingot.

The temperature gradient is high and the solidification zone becomes narrow, making it difficult for the aluminum liquid to crystallize in the liquid flow channel, which will result in the rod being unable to be drawn out;

The temperature gradient is low and the solidification zone becomes wider. When the crystallization extends to the liquid flow channel, it will inevitably cause breakage, even in the crystallizer;

When the temperature gradient changes due to the influence of the pulling speed, the temperature of the aluminum liquid, and the heat dissipation conditions, if the solidification zone moves to the outlet of the crystallizer, the liquid aluminum will leak out and leakage will occur.

Improvements

Through continuous attempts and analysis of the horizontal continuous casting process of 10mm diameter aluminum rods, Luoyang Hongteng concluded that in order to ensure that the aluminum rod horizontal continuous casting process can continue, the following measures can be taken:

Use higher casting speeds

The casting speed of a 10mm diameter aluminum rod is 850-950mm/min, combined with appropriate cooling intensity.

Use short flow paths

The short liquid flow channel can reduce the melt temperature in the furnace and provide conditions for the smooth progress of the continuous casting process.

Optimize crystallizer design

When designing the crystallizer, ensure that there is a large temperature gradient at the entrance and exit of the crystallizer.

Adopt a smaller secondary cooling water spray angle

The secondary cooling water should be sprayed close to the surface of the cast rod at a small angle.

Optimize lubrication system

Use a small lubricating oil hole diameter, use clean lubricating oil, and drain the gas from the oil pipe to the oil hole of the crystallizer before casting.

Summarize

A series of physical and metallurgical changes occur during the horizontal continuous casting of aluminum rods, and there are still many principles and phenomena that need further discussion and research. If you have any questions about the aluminum rod horizontal continuous casting process and equipment, please feel free to consult us.

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