The process of die casting aluminum ingots, the use of aluminum ingot casting production line

Summary. Cast aluminum alloy is an aluminum alloy that is filled with molten metal to obtain parts of various shapes. It has the advantages of low density, high specific strength, good corrosion resistance and casting process, and small restrictions by part structure design.

It is divided into medium-strength alloys based on Al-Si and Al-Si-Mg-Cu;Al-Cu-based high-strength alloy;Al-MG-based corrosion-resistant alloy;Al-Re-based hot-strength alloy. Most require heat treatment to strengthen the alloy, eliminate internal stress in the casting, and stabilize the structure and part size. It is used in the manufacture of beams, gas turbine blades, pump bodies, pylons, wheel hubs, intake lips and engine casings, etc.

It is also used in the manufacture of cylinder heads, gearboxes and pistons of automobiles, housings of instruments and supercharger pump bodies and other parts. Cast aluminum alloy has good casting properties and can be made into parts with complex shapes;No need for bulky add-ons;It has the advantages of saving metal, reducing costs, reducing man-hours, etc., and has been widely used in the aviation industry and civil industry. It is used in the manufacture of beams, gas turbine blades, pump bodies, pylons, wheel hubs, intake lips and engine casings, etc.

It is also used in the manufacture of cylinder heads, gearboxes and pistons of automobiles, housings of instruments and supercharger pump bodies and other parts.

The use of aluminum ingot casting production line.

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Cast aluminum alloy is an aluminum alloy that is filled with molten metal to obtain blanks of various shapes of parts. It has the advantages of low density, high specific strength, good corrosion resistance and casting process, and small restrictions by part structure design. It is divided into medium-strength alloys based on Al-Si and Al-Si-Mg-Cu;Al-Cu-based high-strength alloy;Al-MG-based corrosion-resistant alloy;Al-Re-based hot-strength alloy.

Most of them need to be heat treated to strengthen the alloy, eliminate the internal stress of the casting, and stabilize the structure and part size. It is used in the manufacture of beams, gas turbine blades, pump bodies, pylons, wheel hubs, intake lipes and engine casings. It is also used in the manufacture of cylinder heads, gearboxes and pistons of automobiles, housings of instruments and supercharger pump bodies and other parts.

Cast aluminum alloy has good casting properties and can be made into parts with complex shapes;No need for bulky add-ons;It has the advantages of saving metal, reducing costs, reducing man-hours, etc., and has been widely used in the aviation industry and civil industry. It is used in the manufacture of beams, gas turbine blades, pump bodies, pylons, wheel hubs, intake lips and engine casings, etc. It is also used in the manufacture of cylinder heads, gearboxes and pistons of automobiles, housings of instruments and supercharger pump bodies and other parts.

Last year, Tesla's integrated body technology once again subverted people's perception of innovation, and the original car body was still pure and can be made in this way.

Tesla, on the other hand, uses one-piece die-casting technology.

So what is die casting?

Pressure casting (referred to as die casting) is a kind of casting, which is a method of filling liquid metal or semi-liquid metal into the cavity of the die casting mold at high speed under high pressure, and quickly solidifying the casting under high pressure.

The salient characteristics of the die-casting process are high pressure, high speed and high temperature.

High pressure: It is commonly used for pressures ranging from tens to hundreds of megapascals;

High speed: the filling speed of die casting is about 10-50ms, sometimes even up to more than 100ms, the filling time is very short, generally, high temperature: the temperature of die-casting melted metal is very high, the die-casting temperature of zinc alloy is 400, the die-casting temperature of aluminum alloy is about 610-670, and the die-casting temperature of copper alloy can reach 1000.

The temperature of the mold is generally one-third of the temperature of the alloy.

Understanding these characteristics of the die casting process can help to reasonably design die castings to meet the requirements of the die casting process.

I am more familiar with sheet metal and stamping process before, compared with sheet metal parts, the shape of die casting parts can be more complex, the wall thickness of the parts can change, the strength is better than sheet metal parts, one die casting can replace several sheet metal parts, so as to simplify the product structure. It provides a new reference direction for us to design simpler and stronger products.

Therefore, I think it is very necessary to learn a little bit about die castings.

Aluminum alloy casting processes include sand casting, metal mold casting, die casting, squeeze casting and so on.

1. Sand casting, a casting method for producing castings in sand molds. Steel, iron, and most non-ferrous alloy castings can be obtained using the sand casting method. Because the molding materials used in sand casting are cheap and easy to obtain, the casting manufacturing is simple, and it can adapt to the single production, batch production and mass production of castings, and has been the basic process in casting production for a long time.

2. Metal mold casting, also known as hard mold casting, is a casting method that pours liquid metal into a metal mold to obtain castings. The mold is made of metal and can be reused many times.

3. Die-casting is a metal casting process, which is characterized by the use of mold cavity to apply high pressure to the melted metal. Molds are usually machined from a stronger alloy, a process somewhat similar to injection molding.

4. Squeeze casting, also known as liquid die forging, is a method that makes molten metal or semi-solid alloy directly injected into an open mold, and then closes the mold to produce a filling flow to reach the external shape of the workpiece, and then applies high pressure to make the solidified metal produce plastic deformation, and the unsolidified metal is subjected to isostatic pressure, and high-pressure solidification occurs at the same time, and finally the workpiece or blank is obtained.

Preparation of aluminum scrap First of all, the scrap aluminum is classified and stacked in stages, such as pure aluminum, deformed aluminum alloy, cast aluminum alloy, mixture, etc. For scrap aluminum products, they should be dismantled, the steel and other non-ferrous metal parts connected to the aluminum should be removed, and then scrap aluminum should be made into scrap aluminum through cleaning, crushing, magnetic separation, drying and other processes. The liquefaction and separation of aluminum scrap is the development direction of aluminum metal in the future.

It combines the pretreatment of scrap aluminum miscellaneous materials with re-casting, which not only shortens the process, but also avoids air pollution to the greatest extent, and greatly improves the net metal rate. There is a filter that allows gas particles to pass through, and in the liquefaction layer, the aluminium precipitates at the bottom, and the organic matter such as paint attached to the scrap aluminium decomposes into gas, tar and solid charcoal above 450 degrees.

It is then completely burned through an oxidation device inside the separator. The waste is stirred by the rotating drum and mixed with the dissolved liquid in the silo, and the impurities such as sand and gravel are separated into the sand and gravel separation area, and the dissolving ferry brought out by the waste is returned to the liquefaction bin through the ** propeller.

According to the preparation and quality status of scrap aluminum materials, according to the technical requirements of recycled products, the dosage of various materials is selected and calculated. The oxidative burn loss of silicon and magnesium is greater than that of other alloying elements, and the burn loss of various alloying elements should be determined by experiments in advance. The physical specifications and surface cleanliness of aluminum scrap will directly affect the quality of the recycled finished product and the metal yield.

Up to 20 % of the active ingredient of the degreased aluminium scrap will enter the slag. Recycled deformed aluminum alloy The deformed aluminum alloy that can be produced with scrap aluminum alloy is the main one, of which the main one is the production of 3105 alloy. In order to ensure that the chemical composition of the alloy material meets the technical requirements and the technological needs of pressure processing, a part of primary aluminum ingots should be added if necessary.

Only a small part of the recycled casting aluminum alloy scrap is recycled into deformed aluminum alloy, and about 1 4 is regenerated into a deoxidizer for steelmaking, and most of it is used for recycled casting aluminum alloy. Only a small fraction of the scrap aluminium is recycled into deformed aluminium alloy. The die-casting aluminum alloys A380 and ADCL0 widely used in the United States, Japan and other countries are basically recycled from scrap aluminum.

The main equipment of recycled aluminum generally uses a special static furnace with oil or gas.

Summary. At present, most of the aluminum alloy structural parts in the 3D form of smartphones and their accessories are manufactured by aluminum alloy stamping, aluminum forging, aluminum die-casting and full CNC machining.

The aluminum alloy stamping process is mainly used for most products with the same thickness, and it is difficult to make products with different thicknesses; And it is generally used for the production of thin parts, and is not suitable for structures with high strength requirements.

The process of aluminum forging process is longer, needs multiple forging dies, after each forging is completed, heat treatment must be carried out to eliminate the influence of residual stress, the production cycle is longer, the cost is higher, and it is more difficult to realize for some complex structures.

The solution of full CNC machining has large raw material consumption, long processing cycle, large demand for equipment and high production cost.

The common aluminum die-casting process requires the use of special die-casting raw materials, but the composition of the die-casting raw materials determines the strength of the material, and it is difficult to meet the structure with higher strength requirements.

The process of aluminum die casting small parts.

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At present, most of the aluminum alloy structural parts in the 3D form of smartphones and their accessories are manufactured by aluminum alloy stamping, aluminum forging, aluminum die-casting and full CNC machining. The aluminum alloy stamping process is mainly used for most products with the same thickness, and it is difficult to make products with different thicknesses; And it is generally used for the production of thin parts, and it is not suitable for socks and jujubes for structures that have a high strength demand for Sun. The process of aluminum forging process is longer, multiple forging dies are required, and after each forging is completed, heat treatment must be carried out to eliminate the influence of residual stress, and the production cycle is longer, the cost is higher, and it is more difficult to realize the structure of some complex and complex chains.

The solution of full CNC machining has large raw material consumption, long processing cycle, large demand for equipment and high production cost. The common aluminum die-casting process requires the use of special die-casting raw materials, but the composition of the die-casting raw materials determines the strength of the material, and it is difficult to meet the structure with higher strength requirements.