Aluminum Copper Alloy Casting

Alloys with aluminum and copper as the main components are called aluminum-copper alloys. Casting aluminum-copper alloys is prone to casting defects such as shrinkage cracks and poor filling; this is due to the high copper content, poor fluidity of aluminum melt, and alloys. There is a serious mushy solidification phenomenon in the solidification process; the most suitable casting method needs to be judged according to the specific casting structure, and the suitable process methods for different casting conditions are also different. Qinhuangdao Zhongwei Precision Machinery Co., Ltd. After more than years of precipitation, we have rich experience in the production of various aluminum alloy castings, silicon aluminum alloy castings, aluminum copper alloy castings, aluminum magnesium alloy castings, aluminum bronze castings and other castings. Manufacturers from various countries are expected to inquire about aluminum copper alloy casting.

Product Description

The basic situation of aluminum copper alloy casting

1.Implementation standards: The company strictly implements ISO9001 & TS 16949 certification.

2. Product material standards: ISO, GB, ASTM, SAE, ISO, EN, DIN, JIS, BS

3. Main processes: sand casting, silica sol investment casting, water glass investment casting,shell casting,deburring, sand blasting, machining, heat treatment, leak testing, surface treatment, etc.

4. Available materials:

Aluminum alloy casting, silicon aluminum alloy casting, aluminum copper alloy casting, aluminum magnesium alloy casting, aluminum bronze, tin bronze, silicon bronze, aluminum bronze, brass, red copper, titanium alloy, high manganese steel, high chromium steel, high nickel steel , carbon steel, alloy steel, stainless steel, gray iron, , cast iron, cast steel, cast aluminum, etc. according to customer requirements.

Production Process

The main points of the process of smelting ZL201 alloy are: strictly control the chemical composition and impurity content to prevent titanium segregation and bottom sinking. For this reason, aluminum ingots with higher purity should be used, and the return material should not exceed 60%. When batching, it is necessary to master the accurate melting rate of each element, and check the iron and silicon content. The technological measures to prevent and eliminate titanium segregation are as follows.

(1) It is not allowed to use uneven composition and large flakes. or of poor metallurgical quality

Master alloy; the titanium content is controlled between 0.15% and 0.30% during batching.

(2) Strengthen stirring during smelting, and try to use induction furnace for smelting.

(3) Try to shorten the holding time from stirring to casting, not more than 20 to 30 minutes.

ZL201 alloy is very sensitive to impurities iron and silicon. It is best to use a graphite crucible, which should be cleaned and preheated before feeding.

Copper, manganese and titanium are respectively added in the form of Al-Cu, Al-Mn, Al-Ti master alloys, and titanium can also be added. In order to obtain an alloy with accurate composition and high metallurgical quality, the secondary melting method is commonly used. First, the prefabricated alloy ingot is melted, and the second is rapidly melted. After adjusting the composition, it is cast. Under the condition that the smelting process is mature, the alloy composition can be accurately controlled, and the alloy quality is guaranteed, the prefabricated ingot can be omitted.

Aluminum-copper binary alloys are simpler to manufacture than other cast aluminum alloys. This alloy can be melted in crucibles, flame reverberatory furnaces and electric furnaces of various configurations. Aluminum-copper alloys are not as easy to absorb gas as aluminum-silicon alloys, nor are they easy to oxidize like alloys with high magnesium content. Aluminum ingots of grade A3 and below and copper of grade 3 (M3) and its 'F were used as the charge for the aluminum-copper alloy. Copper is added to the aluminum-copper alloy in the form of an aluminum-copper master alloy. The aluminum-copper eutectic alloy containing 33% copper has all the properties of an excellent master alloy: it can be made into a fusible (melting point 540°C) and brittle alloy with a uniform chemical composition. However, alloys containing 50% copper have greater advantages. At a low melting point (575°C) and sufficient brittleness, this alloy is homogeneous.

There are three possible methods of making the aluminum-copper master alloy: (1) mixing molten aluminum and copper; (2) dissolving copper in molten aluminum; (3) dissolving aluminum in molten copper. Of these three methods, the third method is the most practical because it is simple and guarantees good quality of the master alloy.

The method of dissolving copper in molten aluminum and the method of mixing molten metal make the master alloy susceptible to contamination by non-metallic impurities due to intense overheating of the smelt. The addition of preheated solid copper or molten copper to molten aluminum induces a significant temperature increase due to the dissipation of heat generated by the aluminum-copper alloy. Mixing together separately melted metals, in addition to overheating the alloy, complicates the production process as two furnaces, crucibles, etc. are used. However, when fusing large quantities of master alloys in large foundries, this method makes some sense. In this method, the copper and part of the aluminum are melted separately under the charcoal cladding. The molten copper was poured into the molten aluminum in a thin stream, and the remainder of the solid aluminum was additionally added in batches in order to lower the temperature of the smelt. When solid aluminum dissolves in liquid copper, the heating temperature of the smelt decreases significantly. This is due to the higher heat capacity and latent heat of fusion of copper than that of copper. However, the use of this force method does not avoid the possibility of local overheating of the smelt. To avoid localized overheating, aluminum is added deep below the surface of the molten pool and dissolved in liquid copper.

The method of dissolving solid copper in molten copper to make Al-Cu master alloy is summarized as follows: all copper is charged into the furnace, and 10~15% of the total aluminum of the charge is added to accelerate the melting of copper. The aluminum was added in small amounts as the copper melted, adding the aluminum to the depths of the molten pool and mixing the smelt at this point. The aluminum ingot should be preheated to 150~200℃. After all the aluminum is dissolved, the alloy is smelted to 700°C and refined with zinc chloride, the slag is removed, and the resulting master alloy is cast into a preheated ingot mold at 680-700°C. When the master alloy is solidified in the ingot mold, the film formed on the surface is taken out with a ladle, so that the gas can be released from it as the metal solidifies and the non-metallic contamination on the surface can be removed.

Post Casting Process

1. Heat treatment: annealing, carbonization, tempering, quenching, normalizing, surface tempering

2. Processing equipment: CNC, WEDM, lathe, milling machine, drilling machine, grinder, etc.;

3. Surface treatment: powder spraying, chrome plating, painting, sandblasting, nickel plating, galvanizing, blackening, polishing, bluing, etc.

Moulds and Inspection Fixtures

1. Mold service life: usually semi-permanent. (except for lost foam)

2. Mold delivery time: 10-25 days, (according to product structure and product size).

3. Tooling and mold maintenance: Zhongwei is responsible for precision parts.

Quality Control

1. Quality control: the defective rate is less than 0.1%.

2. Samples and trial run will be 100% inspected during production and before shipment, sample inspection for mass production according to ISDO standards or customer requirements

3. Testing equipment: flaw detection, spectrum analyzer, golden image analyzer, three-coordinate measuring machine, hardness testing equipment, tensile testing machine;

4. Provide after-sales service.

5. The quality can be traced back.

Application

Copper alloys are aluminum alloys with copper as the main alloying element, including aluminum-copper-magnesium alloys, aluminum-copper-magnesium-iron-nickel alloys, and aluminum-copper-manganese alloys, which can be strengthened by heat treatment. Aluminum copper alloy casting has good heat resistance and processing performance, but its corrosion resistance is not as good as that of most other aluminum alloys. Under certain conditions, intergranular corrosion will occur. Therefore, the plate often needs to be coated with a layer of pure aluminum or 6 series aluminum alloy. Improve corrosion resistance. Among them, the aluminum-copper-magnesium-iron-nickel alloy has a very complex chemical composition and phase composition. It has high strength at higher temperatures and good process performance. It is mainly used for heat-resistant parts that work below 150 to 250 degrees Celsius. Although the room temperature strength of the aluminum-copper-manganese alloy is lower than that of the aluminum-copper-magnesium alloy, the strength is higher than the two at 225 to 250 degrees Celsius or higher, and the alloy has good process performance and is easy to weld. It is mainly used in heat-resistant weldable alloys. Structural parts and forgings.