Aluminum alloy flat ingot automatic control casting process parameter setting

[China Aluminum Industry Network] 1, Metal Level

The metal level setting is a crucial parameter that ensures the internal quality of the ingot. It consists of two main stages: the initial level and the level during the casting process. The initial liquid level plays an important role in starting the casting process, commonly referred to as "the beginning." This stage corresponds to the time it takes for the mold to fill and helps establish the base for the casting. During the actual casting, maintaining the correct liquid level is essential to prevent defects such as cold shut or cracking. This is influenced by factors like casting speed, temperature, and cooling intensity. Additionally, the time difference between the undetermined metal level height and the liquefaction alarm height must be considered to ensure safe operation and protect the equipment from damage.

2, Mold Filling Time

Mold filling time, also known as liquid level filling time, is a key parameter used in computer-controlled casting systems. When the liquid level is filled, it has a direct relationship with the metal level height. If the filling time is set to the same value, a higher metal level setting results in a faster injection of molten metal into the mold and a higher temperature inside the crystallizer, which leads to a slower cooling rate under similar conditions. Conversely, a slower flow rate means lower temperatures and faster cooling.

When the metal level height is fixed, a longer filling time means a slower flow rate of the molten metal into the mold, resulting in lower temperatures and faster cooling. On the other hand, a shorter filling time leads to a quicker flow rate, higher temperatures, and a slower cooling rate.

The combination of liquid level filling time and metal level height is used to control the speed at which the liquid fills the mold before casting begins. This initial casting speed is critical in managing the bottom temperature of the ingot. An appropriate initial speed can help prevent issues such as leakage, cracking, and poor shape formation at the bottom of the ingot. The initial casting speed can be adjusted based on various casting conditions, including different casting temperatures, ambient temperatures, and the specific characteristics of the alloy being cast. For example, alloys that are more prone to cracking will require a different initial speed compared to those that are less likely to crack. This adjustment ensures optimal performance and product quality throughout the casting process.

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