Light Metals 2006 Edited by Travis J.

Galloway TMS (The Minerals, Metals & Materials Society), 2006

METAL QUALITY OF SECONDARY ALLOYS FOR Al CASTINGS.

Eulogio Velasco1, 2, Jasmin Proulx3. NEMAK, Arco Vial Km 3.8, Garcia N.L. CP 6600, Mxico. 2 FIC_UANL Av. Pedro de Alba, Cd. Universitaria, San Nicols de los G. N.L. CP 66400, Mxico. 3 ABB Inc. Metallurgical Analyzers. 585 Charest Boulevard East, Suite 300, Qubec, Qubec, G1k9H4, Canada. Keywords: Melting, Cleanliness, Liquid Metal Processing; Degassing, Demagging.
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Abstract High mechanical properties, fatigue, pressure tight and low porosity are requirements of aluminum cylinder heads and blocks related with the quality of liquid metal. With secondary alloys can be possible to reach these characteristics. But, several control stages are necessary from row material (Al scrap) to final stage: liquid metal in the holder furnace. In order to measure the quality of liquid metal, several samples with the PreFil-Footprinter Unit were taken along the route of melting process. The tracking of the process include melting at reverberatory furnace, fluxing, liquid treatment and degassing. The results showed areas to improve with operational practices and new degassing equipments and use of fluxes treatment. Introduction Aluminum-Silicon Alloys for Cylinder Heads and Blocks demand higher mechanical properties, to meet these requirements primary aluminum alloys and many different techniques have been developed. An essential aspect of the material used in aluminum castings is the quality of liquid metal, this can be defined as the degree to which an aluminum alloy is free from alkali metal contaminants, non-metallic inclusions and dissolved hydrogen. Filtration and degassing practices are employed in the cast house as well as the foundry to achieve the required quality levels. To reach this condition , the molten metal has to be treated with process like fluxing with salts, demagging and filtration. Additional treatments like modification and grain refining help to improve some solidification characteristics and performance of the final product. When secondary Aluminum Silicon alloys are used to make castings of high performance, the control begins with the sorting of aluminum scrap, following by a preparation process like magnetic separators, rotational and eddy currents systems, delaquering and finally melting. .During melting some adjustment and additions of silicon and copper are necessary to reach the chemical composition of the alloy [1].Typically the control of and additions of silicon and copper are necessary to reach the chemical composition of the alloy [1].alkaline elements (lithium, calcium and sodium) and impurities (hydrogen and inclusions) have been removed by fluxing with refining agents based chlorine compounds. The development of gas injection pump technology was an efficient way to achieve high levels of quality of metal and today is widely used in aluminum foundries[2]. One way to assess the quality of metal when the final chemical composition is obtained is analyzing solidified samples by metallographic techniques or fractography of thin bars with notches, however these methods consume time, require preparation and some times is possible detect only big inclusions. An alternative technique to evaluate the metal cleanliness is using the PreFil-Footprinter Unit 3. PreFil-Footprinter Operating Principle The Prefil Operating Principle is illustrated in Figure 1. A preheated re-usable crucible with detachable porous filter disc placed at the bottom is ready to measures the cleanliness of liquid metal. The sample could be taken from furnace, ladle or launder,

Figure 1. PreFil-Footprinte Operating Principle 721

pours into the crucible, closes the pressure chamber and runs the test. The unit applies pressure in the chamber when the metal reaches a specific value of temperature, the liquid metal is forced to flow through the detachable porous filter disc.pours into the crucible, closes the pressure chamber and runs the test., and the filtration curve is generated in automatic way. A reference rate curves selected for specific casting process or curves from previous results can be used to classify the metal for clean or less clean metal, these curves can be displayed in the computer screen meanwhile the metal falls in a weigh ladle, the filtration rate of the current test is plotted and compared on real time with the reference curves. If the current curve lies between the reference (clean and less clean), the metal cleanliness is acceptable for the process, in other way, if the new curve lies below the low reference curve (less clean metal), the metal in the furnace requires treatments or cleaning techniques like settling, filtration or fluxing.

Maintain and continually improve the quality of aluminum liquid alloy is one requirement of aluminum casthouse. Traditionally blocks and cylinder heads have been fabricated from prime metal, master alloys and metallic tablets in order to achieve the final chemical composition required. These products are normally based in the system aluminum-silicon, this alloy may contain other elements like zinc, copper or magnesium. Energy consumption and cost savings are concerns and drivers to use secondary alloys with correct chemical limits, low hydrogen, low alkali metals and low inclusions quantity. In order to produce high performance castings with this alloy, different types of aluminum scrap is used as main source and follow next process: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Sorting Sizing (Shredding) Multiple Magnetic Separation Delaquering Melting Transfer Holding and Chemical Adjustments Degassing Final Holding Pouring

Many tests make possible to built a database to determine limits of metal cleanliness found at different stages of process. The database is used as reference or comparison for tracking or footprint of the process and can be used for shop floor quality control. At the end of the test, the assessment can be completed releasing the crucible from the chamber and removing the micro-filter from the bottom. A metallographic examination of metal residues (trapped in the filter) can confirm the results and extend the interpretation. The PreFil-Footprinter Unit is built into a two-part wheeled cabinet is showed in the Figure 2. The upper part of the cabinet houses the user interface console, the crucible preheater, the pressure chamber and the scale tray. The user interface is located at the top of the cart. It integrates control buttons, a computer and its peripherals.

The goal for stages 1 to 4 is cleans the material of free iron, dust and paints. To produce 319 alloy, mix of UBC, frames, plates, shredded automotive castings, silicon and copper are melted in a 80 metric tons reverberatory furnace with side well. In this stage, oxides from melting process have been reported 4. To reach low magnesium content in the bath (increased by UBC in the charge) chlorine additions are used by gas injection pump technology. Additional benefits of melt treatment with chlorine is removal of undesirable impurities, alkali metals and non-metallic inclusions 5. In order to assess the quality of liquid metal, Prefil samples were taken at the end of cycle (chemical composition in spec.). In Figure 3 the curve in this condition lying in the upper zone of reference line, we have a good metal, this condition as a result of refining by chlorine fluxing.

Figure 2. Prefil Unit

Figure 3.Liquid Metal treated with chlorine fluxing. (Values lying over reference line is consider good quality condition)
In the next holding furnace (80 metric tons Rev), melting of internal scrap, risers and runners and other process like filling 722

Melting Process of Secondary Scrap

with liquid metal from secondary smelter, and fine adjustment with copper, manganese and titanium are carried out, these process cause disturbance of surface and film oxides can be formed. A Prefil sample was taken in this furnace. From the graph (Figure 4), it can be seen that metal in this furnace is less clean than metal with demagging, but enough to be considered as clean metal.

These differences are related to bad dispersion of bubbles, turbulence and damage of aluminum film. Using Prefil Unit as a quality tool in the degassing process, parameters like pressure of nitrogen, flow, RPM of lance, impeller conditions, and degassing time were verified, even, some degassing units were revamped or substituted for new ones with better control and sound alarm system in case of failure for nitrogen injection. In this stage, the benefits of use a quality control tool for liquid metal were less dross and dust generation, short cycle time, less hydrogen content, less nitrogen consumption and better quality of metal. Finally, the liquid alloy was evaluated in the holding furnace close to pouring metal in the metallic mold; samples were taken during continuous pouring process and during filling of furnace with transfer ladles. Due to movement, disturbing and splash the condition of liquid surface was affected, some inclusions and film oxides are formed; this situation is depicted in figure 6.

Figure 4. Re-melt and chemical adjustment in Rev Holder furnace. (Values lying over reference line

is consider good quality condition)

Next critical stage is degassing with nitrogen in order to remove detrimental gas hydrogen. Degassing process of ladles (1.6 metric tons capacity) was done in two different units with rotary impeller operating as shows Table 1. Table 1 Parameters of degassing and density result for 319 alloy. Unit 1 Unit 2 Time (min) 12 10 RPM 350 400 N2 Flow (SCFM) 3.6 2.0 Density (gr/cm3) 2.71 2.73 A sample for each unit was taken after skimming, differences in gas content as shows Table 1 and quality of metal were found. Prefil curves in Figure 5 lie below reference line and show metal with oxides and particles.

Reference Line

Figure 6. Filtration curves for holding furnace: Blue (settling), Red (filling with ladle), Black (degasser on). To complete the analysis, metallographic characterization of inclusions was carried out; particles found were aluminum and magnesium oxides, aluminum carbides and aluminum-titaniumbore intermetallics, ranging from 5 to 80 micrometers. These kinds of particles are originated during melting operations and grain refining practices, carbides could be traces of graphite from shafts and impellers used during degassing process. Conclusions. Demagging process not only removes magnesium and alkali metals is too a way to produce high quality metals in secondary alloys. Quality of liquid metal can be affected in different stages of process, degassing and surface condition in holder furnace are critical stages prior to pouring castings. The Prefil-Footprinter is a powerful tool for assess the condition of liquid metal in each stage, from melting to pouring station.

Figure 5. Filtration curves for Degassing Process. Blue and Green lines for Unit 1 and Red for Unit 2. (Values

lying over reference line is consider good quality condition)

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REFERENCES 1.-D. G. Altenpohl Aluminum: Technology, Applications, and Environment 6th Ed. TMS (Warrendale, PA). 2.- D. V Neff, The Use of Gas Injection Pump in Secondary Aluminum Metal Refining, Proceedings, AIME, Recycle and Secondary Recovery of Metal, 1985. 3.-A. Simard et.al. Cleanliness Measurement Benchmarks of Aluminum Alloy Obtained Directly At-Line Using the prefilFootprinter Instrument, Light Metals 2000. 4.- D. L Stewart and K.M. Tomaswick, Quantifying the amount of Oxides in Aluminum, Light Metal 1997. 5.- R.S. Henderson, D.V. Neff and C.T. Vild, Recent Advancements in Gas Injection Technology Using Molten Metal Pumps, Light Metal 2001.

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