Ceramic products for treatment of molten aluminium
TKR developed a special ceramic material for the treatment of
liquid
aluminium: Hi-Cera.
 HI-CERA SERIES
|
| HI-CERA SN |
Material: Silicon nitride advanced ceramics.
Features: Excellent heat shock resistance, corrosion
resistance to molten aluminium alloys, high wear resistance.
Applications: Protection tubes, heater tubes, degassing
rotor shaft and other parts in treating molten aluminium. |
| HI-CERA SN, TB |
Material: TiB2 and TiCN based advanced ceramics.
Features: High hardness, wear resistance and electronic
conductivity.
Applications: Any applications required durability, and
level sensors for molten aluminium alloys. |
Various parts such as thermocouple protection
tubes, heater protection
tubes, stalks and degassing rotor shafts are being used in the
processes
through melting furnaces to casting tables in the aluminium industry.
Silicon
nitride fine ceramics is the best material to suit a variety of demands
like
- outstanding corrosion resistance to molten aluminium alloys
and flux,
- very good gas tightness,
- excellent oxidation resistance up to 800°C and therefore
long lifetime,
- good thermal shock resistance,
- the highest mechanical strength among ceramics,
- very good wear resistance for rotating parts and least but
not last
- an exceptional acid resistance against acids such as HCl and
H2SO4 which allows acid cleaning of the parts.
Thermocouple and Heater Protection Tubes
Hi-Cera SN makes an excellent thermocouple protection tube
considering
the outstanding features. These tubes are maintenance free, have a long
service
life and are easy to handle.
Hi-Cera SN heater protection tubes have
excellent corrosion resistance,
high mechanical strength and outstanding shock resistance. Using this
material
ensures a long lifetime. Hi-Cera SN heater tubes are available for both
vertical
and horizontal applications.
Stalks for low pressure casting
Hi-Cera SN stalks can replace cast iron stalks and old style
ceramic
stalks effectively. The excellent corrosion resistance assures longer
service
life compared to previously used materials. The low wettability to
molten
aluminium makes daily maintenance easier. The adapted flange is
designed
to prevent air leaking and damages by heavy load.
Degassing Rotor Shafts, Wheels and Equipment
Before using the molten aluminium for casting, it is necessary to
remove
hydrogen gas from the melt in order to avoid bubbles in the cast
aluminium
parts. This can be done by using a rotor, rotating in the aluminium
melt
and purging the molten aluminium through the shaft with Argon gas.
Hi-Cera
SN rotor shafts and wheels exhibit exceptional wear and oxidation
resistance
compared to a graphite rotors. They assure stable high hydrogen removal
efficiency and have a long lifetime. The excellent thermal shock
resistance
and the original impeller design permit insertion into and withdrawal
from
molten aluminium without preheating. The original design of the TKR
rotor
wheel results in high gas dispersability and makes hydrogen removal
efficiency
superior. Hi-Cera SN rotor shafts and wheels are suitable for both
in-line
and batch degassing systems.
TKR offers degassing Metaloclean TS equipment
for inline and for batch
processing. In-line degassing units are available with one or two
rotors.
They are designed for an aluminium flow rate between 150 and 400 kg/min
and
use an Argon flow of 10 to 60 l/min Argon per rotor. Batch degassing
units
can take a load of 200 - 1000 kg. Heating of the bath can be done
either
by immersion heating or by gas burner.
Filtering units
The TKR division of Mitsui Kinzoku introduced a highly efficient
filtering
system for molten aluminium called "Metalofilter" in 1972, the result
of
a extensive research and development program. Metalofilter is now
widely
recognized by the aluminium processing industry as an outstanding
system
in terms of improved quality and increased molten metal yield. The
demand
for aluminium of higher quality has recently risen for applications in
airplanes,
cars, window frames, disks, foils, cans and many other products.
Meanwhile,
Metalofilter is the leading aluminium melt filter system in Japan with
a
market share of close to 100% and has been sold also to many customers
worldwide.
The Metalofilter should be installed after
the degassing unit (when
provided), and just before the casting unit. Inclusions or impure
particles
are captured at the surface or in the filter tubes. Inertia
sedimentation
is utilized to capture inclusions in the filter tubes, enabling
particles
smaller than the pores to be filtered out.
Molten aluminium metal is filtered by fused
and regulated alumina bonded
and fired filter tubes according to the grain size and different raw
materials.
Various materials and tube sizes are available. The filter tubes are
installed
in a cartridge with 8, 16 or 28 filter tubes usually. Filtering boxes
for
the installation of filter cartridges are also available from TKR in
several
dimensions for a capacity between 100 and 5400 t/box. The installation
of
the cartridges in the filter box is done using a cartridge hanger,
consisting
of two hydraulic cylinders and a cartridge presser. An aluminium
flow
rate of 16 kg/min per filter tube is normal.
The heating lid incorporates a set of heaters
or gas burners to preheat
the box and/or maintain molten metal temperature. S.C.R. power control
is
utilized. The unit incorporates a digital programmer, distributor and
temperature
recorder. Alarms for abnormal molten metal temperature, current
leakage,
over-current and abnormal thyristor are provided.
| Crystec Technology Trading GmbH will be pleased to further discuss details with you. |
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