During the smelting and transportation process, aluminum and its alloys, oxide scale, intermetallic compounds, lining exfoliation, etc. are easily brought into the aluminum liquid to form non-metallic solid inclusions. Large solid inclusions make the structure of aluminum and its alloys discontinuous, reduce the airtightness of the workpiece, and significantly reduce the strength and plasticity of the aluminum alloy.
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Fine dispersed solid inclusions increase the viscosity of the aluminum liquid, reduce the feeding ability of the aluminum liquid during solidification, and easily cause loose castings. During the smelting of molten aluminum, refining agents are used to treat solid inclusions. During the transportation of molten aluminum, ceramic foam filters, deep bed filtration, tubular filters, etc. are used to remove solid inclusions in molten aluminum. Generally speaking, solid inclusions have Filtration and purification capabilities: tubular filter > deep bed filtration > foam ceramic filter plate.
Compared with deep bed filtration and tubular filters, ceramic foam filter plates have slightly lower filtration and purification capabilities, but they have the advantages of low cost of use and the flexibility to replace aluminum alloy grade series. They are used in some low-end aluminum products with low filtration and purification requirements. It has a wide range of applications in alloy production.
However, the Alumina ceramic foam filters in the existing technology have poor filtration and purification capabilities and cannot replace tubular filters in the production of mid-to-high-end aluminum alloys. This makes the application scope of foam ceramic filters using foam ceramic filter plates small and cannot further reduce the cost of medium and high-end aluminum alloys. High-end aluminum alloy production filtration and purification costs.
Therefore, there is an urgent need for a high-clean foam ceramic filter plate for purifying aluminum liquid and a preparation method thereof to solve the above technical problems.
The purpose is to overcome the above shortcomings and provide a foam ceramic filter plate for purifying high-clean aluminum liquid and its preparation method.
Implementation of the technical plan: ceramic foam filter for high-clean aluminum liquid purification,
The physical phases of the foam ceramic filter plate include kyanite, mullite, quartz, and aluminum borate; the proportion of kyanite is 30-50% of the quality of the foam ceramic filter plate, and the proportion of mullite is 30-50% of the quality of the foam ceramic filter plate. The proportion of quartz is 20-40% of the quality of the foam ceramic filter plate, and the proportion of aluminum borate is 10-40% of the quality of the foam ceramic filter plate.
The physical phases of this ceramic foam filter are kyanite, mullite, aluminum borate, and quartz. Among them, kyanite, mullite, and quartz are skeleton fillers, aluminum borate is a high-temperature binding agent, and aluminum borate has a whisker structure. The diameter of aluminum borate whiskers is 2-5 μm, and the length of aluminum borate whiskers is 20-100 μm.
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The average size of the surface pores of the foam ceramic filter plate is 500-100 μm; the foam ceramic filter plate has pores inside, and the pores have a three-dimensional connected structure. The cell walls of the foam ceramic filter plate have protrusions and micropores. The thickness of the channel wall is 80-100μm; the micropore size is 5-50μm.
The internal channels of the foam ceramic filter plate have rough walls, a loose structure, and bulges and micropores. The micropore size is 5-50 μm, which can filter and adsorb smaller solid inclusions. The filtration efficiency of 5 μm solid inclusions is ≥80%.
Preferably, the foam ceramic filter plate has a volume density of 0.3-0.4g/cm3, a normal temperature compressive strength ≥1MPa, a high-temperature compressive strength ≥0.5MPa, and a high-temperature flexural strength ≥0.5MPa.
Kyanite, mullite, and quartz have low density, and the foam ceramic filter plate has low volume density, high mechanical strength, and good thermal shock resistance. The loss of compressive strength at room temperature after thermal shock is ≤20%;
The main phases of this ceramic foam filter are kyanite, mullite, quartz, and aluminum borate. The interior of the foam ceramic filter plate has a three-dimensional connected pore structure, rough pore walls, low firing temperature, low volume density, and mechanical strength. It has the characteristics of high efficiency, excellent thermal shock performance, and high filtration precision; it uses aluminum borate as the binder, which avoids phosphorus corrosion of equipment and environmental pollution during the production process compared with traditional phosphate-bonded alumina foam ceramic filter plates.
The filtration and purification capacity of this foam ceramic filter plate has been improved, and it can replace the tubular filter in the production of mid-to-high-end aluminum alloys. It not only broadens the application scope of foam ceramic filters but also greatly reduces the filtration and purification in the production of mid-to-high-end aluminum alloys. cost.
Beneficial effects:
(1) It can achieve filtration and purification of 5 μm solid inclusions. In the production process of high-clean aluminum liquid, the filtration and purification cost per ton of aluminum liquid is reduced from 50 yuan to 20 yuan, which is a 60% reduction;
(2) It can replace tubular filters, facilitate the alternate production of different grades of aluminum alloys, and adapt to market demand;