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Online monitoring and real-time feedback on inclusions in molten metal are essential for metal quality control. However, existing methods for detecting aluminum melt inclusions face challenges, including interference, prolonged processing times, and latency. This paper presents the design and development of an online monitoring system for molten metal inclusions. Initially, the system facilitates real-time adjustment of signal acquisition parameters through a multiplexer. Subsequently, it employs a detection algorithm capable of swiftly extracting pulse peaks, with this task integrated into our proprietary host computer software to ensure timely detection and data visualization. Ultimately, we developed a monitoring device integrated with this online monitoring system, enabling the online monitoring of the aluminum alloy filtration process. Our findings indicate that the system can accurately measure the size and concentration of inclusions during the filtration process in real time, offering enhanced detection speed and stability compared to the industrial LiMCA CM (liquid metal cleanliness analyzer continuous monitoring) standard. Furthermore, our evaluation of the filtration process demonstrates that the effectiveness of filtration significantly improves with the increase in inclusion sizes, and the synergistic effect of combining CFF (ceramic foam filter) and MCF (metallics cartridge filter) filtration methods exceeds the performance of the CFF method alone. This system thus provides valuable technical support for optimizing filtration processes and controlling inclusion quality.

The oxide film on the scrap surface is one of the primary sources of oxide inclusions in the aluminum melt. Understanding the evolution of the oxide films in the aluminum melt is an important step for developing efficient recycling technologies and controlling the quality of the product. In the present study, we studied the evolution behavior of the oxide film in the aluminum melt. The oxide films were introduced via aluminum alloy scraps into the melt, and the micro-morphology and composition of the oxide film were analyzed by scanning electron microscope and energy spectrum. Results show that the oxide film on the surface of 1235 alloy foil, A356 alloy turning, and 5083 alloy scalping were broken into small flake oxide film and then transformed into minor granular oxide when the scraps were charged into commercial purity aluminum melt. However, in aluminum alloy melt containing magnesium, the oxide film remained an intact sheet shape up to a certain melt dwelling time.