Conjugated Heat Exchange in Heat Treatment of Aluminum Ingots Simulation

Casting aluminum to obtain semi-finished products - round ingots, due to uneven cooling in the mold, leads to various defects that affect further machining. To eliminate such defects, heat treatment is carried out - homogenization annealing. One of the homogenization important stages is the cooling of the ingots after heating at a rate that does not lead to the ingot quenching. The cooling medium is air. Knowing the conditions of heat exchange between the cooling air and the high-temperature aluminum billet makes it possible to obtain the ingot’s necessary physical and mechanical properties. The article describes the developed mathematical model of conjugate heat transfer during homogenization annealing of aluminum ingot. It allows analytically calculating the temperature of the ingots depending on the cooling time. To verify the data obtained by the mathematical model, the conjugate heat transfer in the ANSYS program was simulated.

Casting of recycled aluminum, Al + Cu + Mg alloy formation and lamination process of an electric current conductor

This research presents a methodology for the recycling process via casting, in which aluminum cans and primary (commercial) aluminum are transformed into a laminated tape, with the possibility of industrial application. This research was classified as bibliographic, exploratory, and experimental, since it used qualitative techniques to evaluate alternative materials. Its objective was to incorporate materials of different properties that could favor the making of a tape to be laminated. In the first casting, a recycled aluminum ingot was formed only with aluminum from beverage cans and had a material yield of 51%. In a second casting, commercial aluminum was added to the recycled aluminum ingot. After the casting process with the two cast materials, the ingot had a yield of 90%. A third casting was conducted together with the aluminum that was already formed by the ingot (50% recycled and 50% commercial). The purpose of this ingot was to incorporate other materials that could provide some characteristics, such as malleability and conductivity. The third casting was made from the second ingot, and incorporated copper and magnesium. For the design of the laminated tape, a cast was made to receive the molten aluminum from the third casting. The aluminum was cast into this mold and three tapes were produced, one with a thickness of 2 mm, another with a thickness of 3 mm and the last with a thickness of 4 mm. With these tapes, the objective was to laminate them in order to reduce their thickness to values ​​close to 0.5 mm. The casting process of aluminum cans with the addition of commercial aluminum, plus the incorporation of copper and magnesium, demonstrated facilities for thickness reduction in the process of making laminated tapes.

Mask Gradient Response-Based Threshold Segmentation for Surface Defect Detection of Milled Aluminum Ingot

The surface quality of aluminum ingot is crucial for subsequent products, so it is necessary to adaptively detect different types of defects in milled aluminum ingots surfaces. In order to quickly apply the calculations to a real production line, a novel two-stage detection approach is proposed. Firstly, we proposed a novel mask gradient response-based threshold segmentation (MGRTS) in which the mask gradient response is the gradient map after the strong gradient has been eliminated by the binary mask, so that the various defects can be effectively extracted from the mask gradient response map by iterative threshold segmentation. In the region of interest (ROI) extraction, we combine the MGRTS and the Difference of Gaussian (DoG) to effectively improve the detection rate. In the aspect of the defect classification, we train the inception-v3 network with a data augmentation technology and the focal loss in order to overcome the class imbalance problem and improve the classification accuracy. The comparative study shows that the proposed method is efficient and robust for detecting various defects on an aluminum ingot surface with complex milling grain. In addition, it has been applied to the actual production line of an aluminum ingot milling machine, which satisfies the requirement of accuracy and real time very well.

Effect of Combined Electromagnetic Fields on Microstructure and Properties of Large-Sized Ingot of 2219 Aluminum Alloy

Large-sized 2219 aluminum alloy ingot has wide application prospect in aerospace and military fields. Severe defects, such as coarse grain, the inhomogeneity of structure and macrosegregation occurred in large-sized aluminum ingot produced by normal DC casting. The application of a single magnetic field in DC casting process cannot solve these defects. In this paper, a new method with the combination of electromagnetic fields imposed on bulk melt treatment during DC casting was proposed. And a φ508 mm ingot of 2219 aluminum alloy was prepared in this method. Compared with the normal DC casting, the effect of the combined electromagnetic fields on the microstructure and properties was studied. The experimental results demonstrate that the application of the combined electromagnetic fields significantly refines the grains, and the grain size distribution on the cross section of the ingot tends to be more uniform as well as the mechanical properties are significantly improved. The microstructure and grain size distribution can be significantly affected by different combined electromagnetic fields. It is considered that the appropriate combined electromagnetic fields parameters play an important role in controlling the homogeneity of large-sized ingots.

The Effect of the Additional Processing during the Crystallization of a Melt of the AD0 Aluminum Alloy on the Size of Grains

During the process of the aluminum ingot manufacturing obtaining of a fine-grained structure has a huge significance for effectiveness of the further rolling process. The reduction of the grain size leads to an increased plasticity and higher grades of deformability. Today the multiple methods of improving the casting process are being developed varying from mechanical to physical or chemical methods, and their choice depends on different factors. However, the effect on the size of grains of the multi-factor impact was not described in literature. This paper investigates methods of casting including piston pressing with simultaneous exposure to the weak pulsed currents from electromagnetic field during crystallization of melted metal for the first time. The fine-grained uniform over the cross-section structure was achieved in the AD0 alloy ingots.

Dynamic Simulation of the Stack-Manipulator to Aluminum-Ingot Based on ADAMS

On the research and development of the Stack-Manipulator to Aluminum-Ingot, the Stack-Manipulator 3D model was established by using SolidWorks and imported into ADAMS via the interface between them. And then the authors got the torque and angular velocity curves after adding the driving and constraints. Finally, this paper chose the servo motors by using the simulated results. The results provide a reliable and scientific basis for the development of the control system.

The Simulation of Stack-Manipulator to Aluminum-Ingot Based on ADAMS

The authors build the three-dimensional model of stack-manipulator to aluminum-ingot in SoildWorks,and then import the model into Adams to create a simulation model via the interface between them.Adams runs dynamic and kinematics simulation of the model to measure some kinematic data of manipulator and the contact force of gear part.The dynamic simulations have forecasted the performance of products based on the model well and show the importance of Adams in product development.