Hot top Aluminum Billet Casting Machine 5 Inches Billet Casting Table

Product Specification

Hot top aluminum billet cooling casting table 5 inches

Product introduction

1.1. The supply of the casting platform includes all crystallizers, aluminum liquid distribution systems, cooling water distribution systems, and ingot casting systems.
1.2. The crystallizer is a dual piece water curtain crystallizer made of aluminum alloy; The crystallizer raw material is forged using 6061 aluminum rod. The raw material is first rough machined, and then CNC drilling and milling work and precision machining are carried out.
1.3. The cooling ring is processed with purple copper;
1.4. All refractory materials are prefabricated components made of "Zhongnai No.1".
1.5. The thickness of the upper plate of the water tank is 25mm, and the thickness of the lower plate is 14mm. The water tank is welded as a whole, and after welding, it is first hot-dip galvanized, then manually annealed and straightened, and finally processed at the assembly position of the crystallizer through a CNC gantry machining center.
1.6. The lead frame is a safety net structure with a height of 800mm, welded with 14mm and 10mm steel plates, and then milled flat on the assembly plane.
1.7. The thickness of the prefabricated pressure plate for the "splitter plate" is 10mm.
1.8. The ingot head is of automatic alignment type, and the material of the ingot head is 45 # steel.
1.9. The water tank and the ingot holder are connected by four bolts for overall assembly and disassembly.
1.10. The water tank is positioned on its working plane through four additional fixed pulleys.

FAQ 

1. What are the key points of daily inspection?

Aluminum liquid temperature/level, flow channel/filtration, crystallizer (water temperature/pressure/flow rate), casting speed/traction, and surface quality of cast rod.

2. What is the regular maintenance cycle?
Daily: Clean the slag from the furnace mouth/flow channel; inspect the burner, ignition system, and seals.
Weekly: verify thermocouples/temperature control instruments; clean the scale in the water gap of the crystallizer; check the integrity of the filter plate.
Monthly: Conduct a comprehensive inspection of the lining thickness/cracks; calibrate the casting speed and traction synchronization; replace aged sealing rings/gaskets.
Every year: overhaul the furnace body (repair/reline the furnace lining); conduct a comprehensive inspection and maintenance of the casting machinery and electronic control system.

3. Safety precautions?
High temperature protection: Wear high temperature resistant clothing, protective face masks, and heat-insulating gloves to avoid burns.
Explosion protection: Leakage is strictly prohibited in gas furnaces, and regular leak detection is required; moist materials are prohibited inside the furnace to prevent explosions caused by water encountering aluminum liquid.
Emergency response: Equip with dry powder fire extinguishers and dry sand.

4. The reason of the dimensions of the cast rods out of tolerance (ellipsoidal, bent, uneven diameter)?
Reasons: deformation/wear of the crystallizer, uneven cooling water, unstable casting speed, asynchronous traction machine, uneven base.
Solution:
Crystallizer: Regularly inspect the roundness/wear of the inner wall, and replace it promptly if it exceeds the tolerance; clean the scale from the water gaps to ensure uniform cooling.
Speed / Traction: Stabilize the casting speed, calibrate the synchronicity of the traction machine; ensure the base is level and reduce vibration.

5. The reason of cast rod porosity / shrinkage cavity (internal voids, poor density)?
Reasons: Excessively high pouring temperature, too fast casting speed, insufficient cooling, poor shrinkage compensation, and a wide solidification range of the alloy.
Solution:
Temperature / Speed: Reduce the pouring temperature, appropriately decrease the casting speed, and extend the solidification time.
Cooling: Enhance the cooling intensity of the crystallizer to ensure sufficient secondary cooling; optimize the water flow distribution in the crystallizer.
Shrinkage compensation: Design the runner reasonably, strengthen the riser for shrinkage compensation, and reduce shrinkage cavities.