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 includes the initial liquid level and the level during the casting process. The initial liquid level plays an important role in starting the casting process, often referred to as "the beginning." It corresponds to the time it takes for the mold to fill and helps establish the base of the ingot. During the casting process, maintaining the correct liquid level is essential to prevent cold shuts or cracks. This parameter is closely related to casting speed, casting temperature, and cooling intensity. Additionally, the time difference between the metal level's undetermined height and the height at which a liquefaction alarm is triggered should also be considered to ensure safe operation and equipment protection.

2. Mold Filling Time

Mold filling time, also known as liquid level filling time, is a key parameter used in computer-controlled systems. When the liquid level fills, it has a direct relationship with the set metal level height. If the filling time is the same, a higher metal level setting means faster liquid injection into the mold, resulting in a higher temperature inside the crystallizer and a slower cooling rate, assuming all other conditions remain constant. Conversely, a slower flow rate leads to lower temperatures and faster cooling.

When the metal level height is fixed, a longer filling time results in a slower flow rate of liquid entering the mold, lower temperature inside, and faster cooling. On the contrary, a shorter filling time means a faster injection rate, higher temperature, and slower cooling. The combination of liquid level filling time and metal level height is used to control the filling speed before the casting begins. The initial casting speed is particularly important for controlling the bottom temperature during the start of casting. A suitable initial speed can help prevent defects such as leakage, cracking, and poor shape at the bottom of the ingot. The initial casting speed can be adjusted based on various casting conditions, such as different casting temperatures, ambient temperatures, and other factors. It may also vary depending on the alloy type, with alloys more prone to cracking requiring a different initial speed compared to those less likely to crack.

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