[Technology] Feeding of Magnesium Alloy Melting

1. Newly opened charge. The standard size for magnesium alloy ingots is typically between 4 to 12 kg per spindle. As an example, we will use AZ91D die-casting magnesium alloy ingots that weigh 7 kg each to explain the process of charging a new furnace.

First, take 30 dried magnesium alloy ingots and cut them in specific ratios—some at 1/3 and 2/3, while others are cut in half. Ensure the surface of the ingots is clean, free from any foreign materials, moisture, or residual magnesium. Before loading, thoroughly clean the crucible to remove rust, oil traces, water, and any debris. Begin by laying a layer of whole ingots at the bottom of the crucible. Then, place 2/3 of the remaining material along the sides of the crucible. Fill in the gaps between the ingots and between the ingots and the crucible wall using the smaller pieces (1/2 and 1/3 sizes). This arrangement helps minimize air gaps and ensures better contact between the alloy and the furnace walls, improving heat transfer efficiency, as shown in Figure 12-3. After loading, clean the furnace lid and ensure it is properly closed to prevent contamination. Also, wipe the top surface of the furnace to maintain cleanliness.

2. Feeding during production. Before adding new materials, preheat the furnace to 150–200°C to eliminate moisture and avoid magnesium splashing, which can be dangerous. Always wear appropriate protective gear when handling materials to ensure safety.

When adding magnesium alloy ingots, do so slowly and carefully—never drop them into the furnace from the air. The liquid level inside the crucible should be kept about 50–60 mm below the top edge to prevent overflow. The amount of material added should be based on the production cycle and the size of the castings. Avoid overloading the crucible in one go, as this can lead to uneven melting and potential operational issues.

Proper feeding techniques not only improve the quality of the final product but also extend the life of the furnace and reduce maintenance needs. It's essential to follow these steps consistently to maintain a safe and efficient production environment.

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