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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. [ABSTRACT FROM AUTHOR]

In A356 aluminum alloy, the effect of electromagnetic stirring process on the melt quality such as density index, hydrogen and oxygen content, and the inclusion amount were investigated. To determine the optimal EMS condition for the aluminum alloy, a numerical study of EMS was applied and the electromagnetic force strength, which is the main source for stirring the melt, was predicted according to the EMS application conditions. In this study, the melt cleaning effect of the EMS process was analyzed by measuring the cleanliness of the solidified A356 alloy samples cast with and without the EMS process. After applying EMS process, the deviation of density index (DI) and hydrogen content in the cast samples according to the specimen position decreased, and it was confirmed that EMS was effective in homogenizing molten metal quality. In the case of the center of the top position, the hydrogen content in the sample decreased by 39.8% after EMS application, and a clear degassing effect was observed. Compared to the cast sample without EMS application, the amount of inclusions decreased by 40 to 55% when EMS was applied. From this, it can be concluded that EMS process has the effect of homogenizing and improving molten metal quality. [ABSTRACT FROM AUTHOR]

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. [ABSTRACT FROM AUTHOR]

Aiming at the problem that melt inclusions in the casting process of 7085 aluminum alloy seriously affect the ingot quality, this study introduces ultrasonic bending vibration into the melt of the launder in the semi-continuous casting process of 7085 aluminum alloy and investigates the online purification effect of ultrasonic bending vibration on the melt of 7085 aluminum alloy through a metallographic analysis, SEM analysis, and EDS energy spectrum analysis. The results show that, under the action of the ultrasonic, the inclusions in the aluminum melt are transformed from a large number of elongated large inclusions with a size of more than 50 μm, and granular inclusions with a size of about 5–15 μm, into a small amount of smaller than 30 μm point-like small inclusions. In addition, the average area ratio of inclusions in the melted sample was reduced from 3.835 (±0.05)% to 0.458 (±0.05)%, and the residual refining agent in the aluminum melt was effectively removed. It was also found that under the action of ultrasonic bending vibration, the tiny inclusions in the melt aggregate with each other, and interact with the residual refining agent in the melt to further grow, and are attached to the inner surface of the ceramic cavity channel to be removed. [ABSTRACT FROM AUTHOR]

[Display omitted] • An island-like oxide nucleation mechanism is found during the oxidation of aluminum melt. • The growth of the oxide obeys an island-by-layer model through the inwards O diffusion. • The oxidation kinetics switches from a linear law to a logarithmic law after the nucleation stage. Understanding on oxidation is critical for the improvement of aluminum melt quality which determines the properties of the aluminum alloy processed by casting. However, the oxidation mechanism of aluminum melt is still unclear in atomistic scale. In this work, we performed reactive molecular dynamics simulation to investigate the oxidation mechanism of aluminum melt on an atomic scale. Our results focus on the island-like nucleation on the melt surface and the following growth of the oxide film. The oxide grows via ion diffusion and the diffusion of O anions plays a greater effect. The evolution of the diffusion coefficient indicates an island-by-layer growth on the aluminum melt. Kinetically, the oxide growth obeys a linear law during the nucleation stage and switches to a logarithmic law after a closed oxide film forms. Besides, we emphasize the effect of oxygen content and ambient temperature on the formation of oxides. Our research can provide insights into the atomic-scale oxidation mechanism of aluminum melt which contributes to the better design for anti-oxidation methods during casting and the oxide-based functional materials. [ABSTRACT FROM AUTHOR]