Ceramic products for treatment of molten aluminium
Crystec

Mitsui Kinzoku TKR Division is represented in Europe by
Crystec Technology Trading GmbH

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Ceramic products for treatment of molten aluminium

TKR developed a special ceramic material for the treatment of liquid aluminium: Hi-Cera.

ceramicHI-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

stark

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.

vertical tube heater

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.

Stalks for low pressure casting

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.

Hi-Cera rotor

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.

degassing unit

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.

aluminum filtration

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.

filter for liquid aluminium

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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