Ultrasonic metal melting homogenizer machine for liquid processor with lifting stand

Ultrasonic metal melting homogenizer machine for liquid processor with lifting stand

Ultrasonic aluminum melt processing equipment utilizes the propagation and action characteristics of ultrasonic waves in liquid metal to achieve various treatment effects on molten aluminum. Specifically, its operating principles include the following:
Cavitation effect: When ultrasonic waves propagate through molten aluminum, they generate alternating positive and negative sound pressures, causing tiny bubbles in the liquid to rapidly collapse under high pressure, generating localized high temperatures, high pressures, and microjets. This cavitation effect removes gas and inclusions from the melt, purifying it.
Acoustic streaming effect: Ultrasonic vibrations induce liquid flow within the molten aluminum, a process known as acoustic streaming. Acoustic streaming promotes uniform mixing of the melt, achieving a more uniform composition within the molten aluminum and reducing compositional segregation.
Mechanical vibration effect: The high-frequency vibrations of ultrasonic waves are transmitted to the molten aluminum, generating mechanical vibrations. This mechanical vibration helps break down coarse grains and refine them, thereby improving the microstructure and properties of the aluminum.
Equipment Components: Ultrasonic vibration components include an ultrasonic transducer, an ultrasonic horn, and a tool head. The transducer converts the electrical energy input from the generator into mechanical energy, namely ultrasonic waves. This energy typically moves back and forth in a longitudinal direction, with an amplitude of several microns. The horn amplifies the amplitude, isolates the molten metal from heat transfer, and stabilizes the entire ultrasonic vibration system. The tool head is connected to the horn, which transmits the ultrasonic energy vibration to the tool head, which then transmits the ultrasonic energy into the molten metal.

The ultrasonic generator: Generates a high-frequency ultrasonic signal, providing energy for the ultrasonic vibrating components. Parameters such as output power and ultrasonic frequency can be controlled to meet different processing requirements.

Equipment Advantages

Improves Product Quality: Significantly refines the grain size, making the aluminum product's structure more uniform, reducing defects such as porosity and inclusions, and improving the aluminum's strength, toughness, and ductility, thereby enhancing the overall performance of the product.

Optimizes Production Process: Simultaneously achieves multiple functions, including degassing, refining, and homogenization, streamlining the process, shortening production time, and improving production efficiency. Reduced Production Costs: Replaces traditional Al-Ti-B refiners, reducing slag volume by 30%-50%, while also reducing fuel, electricity, and other energy consumption, as well as labor and equipment maintenance costs.
Environmentally Friendly: No toxic emissions, making it more environmentally friendly.
Easy Installation: Connects to existing production lines via standard flanges, eliminating the need to modify existing production equipment or processes, making it easy to retrofit and apply to existing production lines.
Applications:
Aluminum Alloy Casting: Produces high-quality ingots, reduces casting defects such as porosity and shrinkage, improves the yield rate of castings, and improves the surface quality of ingots, resulting in a smoother surface. It is highly effective for casting billets, blooms, and slabs.
Aluminum Extrusion: The treated aluminum melt improves the surface quality and dimensional accuracy of extruded products, ensuring that the extruded aluminum meets high-precision requirements.
Automotive Lightweighting: Provides strong support for the production of high-performance aluminum alloy parts, helping to improve vehicle fuel efficiency and safety, and meeting the automotive industry's demand for lightweight, high-performance materials. Aerospace: It helps to manufacture high-strength and high-reliability aluminum alloy structural parts, meeting the strict requirements of the aerospace field on material quality and performance.

Parameter:

When selecting the appropriate ultrasonic equipment for treating molten aluminum, you need to comprehensively consider technical parameters such as power, frequency, and processing capacity. You should also consider factors such as equipment quality and ease of use. The following are key points:
Power Selection: Higher power generally results in higher processing efficiency, but also greater energy consumption and correspondingly higher costs. This power requirement is determined based on production scale and processing requirements. Generally, small laboratory equipment may have a power of 1000W-3000W, while large-scale industrial production equipment can reach several kilowatts or even higher.
Frequency Selection: Ultrasonic frequencies typically range from 20kHz to 100kHz. Low-frequency ultrasound has stronger energy and a more pronounced cavitation effect, making it more effective in removing impurities and gases and breaking up grains. High-frequency ultrasound can more precisely target tiny particles in the melt, resulting in better refinement. When treating molten aluminum, a common frequency is around 20kHz. The frequency can be selected based on specific process requirements.

Processing Capacity Matching: Select equipment with the appropriate processing capacity based on the single batch volume of molten aluminum to be processed during production. If the processing volume is small but the equipment capacity is large, energy waste and costs will increase. Excessive processing volume that exceeds the equipment's capacity will not achieve the desired processing results. Refer to the equipment manual for parameters such as the appropriate crucible size and melt volume to determine appropriate processing results.
Equipment Material Considerations: Due to the high temperature of the molten aluminum, the equipment parts that come into contact with the melt must possess excellent heat and corrosion resistance. Tool heads are generally made of high-strength titanium alloy, capable of withstanding temperatures around 800°C and exhibiting strong corrosion resistance, ensuring long-term, stable operation.

Equipment Quality and Stability: Choose a well-known brand and a reputable manufacturer. Their equipment offers greater assurance of manufacturing processes and component quality, resulting in higher stability and reliability. Learn about the equipment's service life and failure rate, and consult with other users about their experiences.