SOME QUESTIONS ENCOUNTERED DURING ALUMINUM BILLET PRODUCTION PROCESS

​

• What are the physical and chemical properties that should be considered in the choice of raw materials and secondary materials and  what effects can these have on the extrusion profile production speed, profile surface and mechanical properties?

• What are the effects of the method followed for loading aluminum raw materials into melting furnaces, on natural gas consumption, furnace performance and service life?

• What are the critical points to be considered in the preparation of samples and spectrometric analysis  when sampling from melting furnaces?

• What kind of alloy materials should be added in what form and when, and what are the effects of alloying, slag removal, furnace controls on the performance of the  melting furnace. What should be done for practical serial work in these processes?

• What additional equipment should be used in and around the furnace to increase the melting rate?

• Under what conditions is the slag removed from the melting furnace, with the least metal losses? What should be the best method and timing?

• In which areas  and how should continuous improvements be made in the foundry for the lowest natural gas consumption in aluminum melting? What are the important  parameters in the selection of furnace refractories?

• What should be considered in order for the refractories in liquid metal baths to have a long service life?

• What kind of controls and preparations should be made before the transition to casting after the melting process? What are the casting conditions that must be stable while the billet casting continues?

• What are the runner dimensions and refractory properties suitable for the liquid metal flow requirement in billet production? What level of heat loss in the runner can be considered normal? How can production be started without going to high temperature in the furnace at the beginning of casting?

• During the liquid metal flow from the furnace, how should the grain refiner be added and its properties, and where and in what proportions  should be added? How should the amount of grain refiner be calculated? How accurate is it to add grain refiner based on the liquid metal analysis in the furnace?

• What are the most effective gas and pollution removal conditions in the degassing process in the runner? Is it possible to understand the effectiveness of degassing during casting? What should be considered for long-lasting consumption of consumables used in degassing process?

• How to make sure that the impurities in the liquid metal are removed during the use of the ceramic filter? How to detect workmanship errors and inefficient use?

• What is the acceptable liquid metal temperature difference between the furnace outlet and the casting table runner inlet? How effective are the heaters made to reduce this? How much can a liquid metal flowing between 250 kg and 500 kg per minute be heated in a minute or two in the runner?

• What are the things to be considered while casting is starting and continuing? What are the controls that affect the billet surface and internal structure quality in airslip and hottop casting?

• What should be the casting conditions for the mechanical properties and surface expectations of all kinds of profiles?

• In the casting tables in the best categories, is there a full harmony between the cooling, casting speed parameters obtained from the automation system and the values that occur during casting, and how can it be continuously monitored?

• How to check  for accuracy of water flow rates on all molds on the casting table?

• How should production recipes,  be prepared with thermodynamic calculations_cc781905-5cde-3194-bb358_136bad5 for 7xxx series and  commonly used 6xxx special alloys in EU norms called hard?

• During casting and homogenization, what are the effects of cooling conditions on the surface and mechanical properties of the profile in extrusion? What kind of profile surface defects can be caused by billet quality?

• How can the surface color and tone differences that occur in anodizing be reduced on the alloy side?

• What are the effects of the levels of elements in Billet analysis on profile mechanical properties and anodized coloring?

• How can changes be made in the alloy for the required profile properties by staying within EN 573-3 standards ?

• What should be considered in casting molds and liquid metal parameters for the production of unchanging chemical analysis, internal structure smoothness, crack-free smooth surfaced billet during casting?

• What kind of changes should be made in billet analysis and homogeneous heat treatment, while staying within the scope of EN 573-3 for EXTRUSION SPEED increases?

• What should be the ideal homogeneous temperature, holding time and cooling rates for each separate alloy after Billet Casting?

• How to ensure traceability from foundry to extrusion?

• How to do casting operator training from the beginning, what kind of ways should be followed?

• What are the occupational safety measures in the foundry? Where are the significant risks?

•  NOT: Comments and evaluations about the above questions can be shared by e-mail.  Contact: kemal.ors@billetdokum.com