Many tonnes/ann of aluminium are processed with DC casting methods for the productions of slabs.
These solid geometrical elements are largely involved in the production of various industrial sectors, as tranportation, automotive, packaging, construction and aereospace.
The role of Almec Tech is to provide technology and high precision equipments for the casting process of slabs.
The dimensions of the desired equipment are possible to be adapted to different necessities. AT technicians can realize diffent heights and lenghts to comply to the specificity of the cast house project.
EQUIPMENTS COMPONING THE MACHINE
A number of 6 equipments, are specificly dedicated to slab casting process. They represent the core of the casting machine.
The 6 equipments are:
Starting head holder frame
A combination of elements representing the base where starting heads are pinned. It is provided of a frame where all elements are places, a support base for starting heads and centering pins for staring heads frame positioning.
Moulds holder frame
A combination of elements representing the base where moulds are pinned. It consists in a frame holding all elements, centering pins for lauder positioning, centring holes for starting heads frame connection and oil connection.
The distribution launder is where melt aluminium flows, reaching finally the moulds. It is made of a load-bearing support structure and of a heat-resistant modular refractory material. The safety and resistance of the launder is guaranteed by insulating finishing works, such as adding a sheet of specific seals between the refractory parts and plastering any existing gap. It is fundamental to ensure the integrity of the launder before installation, in order to avoid cracks causing melt aluminium to overflow.
Adjustable or Fixed mould
The mould is the master where the final shape of the slab is originated. The geometric element is provided of an internal water circuit for cooling and solidification as “water blade” to make the flux and the water distribution more uniform. On the mould is applied a thin layer of lubricant distributed through the graphite, in order to lubricate correctly during cast.
Two different formats of mould are available:
WALL C MOULD: It is designed to be versatile and performing for the production of Soft and Hard Alloy. It is made up of four elements in aluminum alloy, machined on high precision numerical control machines, joined together by means of special fasteners. Its first contact wall in aluminum is lubricated through a system of graphite inserts.
The secondary cooling consists of supply chambers in series to favor a homogeneous distribution of the water in all areas of the mould. The balancing of the flows is proved to be of primary importance for the metallurgical characteristics of the product.
The dimensional variation of the mould format can be Proposed in the types:
- Modular with variable length;
- Fixed modular.
ACS GH MOULD: It is designed to be versatile and performing for the production of Soft and Hard Alloy. It is made up of four elements in aluminum alloy, machined on high precision numerical control machines, joined together by means of special fasteners. The mould ACS GH is made of high quality graphite inserts which guarantee better surface and structural results. A special treatment is carried out on the graphite surface to improve its heat exchange, thus increasing the performance of the mould with a consequent improvement in cortical segregations.
The dimensional variation of the mould format can be performed manually, usually for existing systems or automatically, by performed by positiong.
Proposed in the types:
- Modular with variable length. It guarantees greater production flexibility for formats of various thickness and width, according to specific needs;
- Fixed modular, for products with standard dimensions.
Adjustable or Fixed starting head
Its shape can provide a uniform distribution of the molten metal during first filling and start cast. On its sides, particulars holes easy the removal of the starting heads during maintenance.
Almec Tech manufactures all types of starting heads, according to the specific needs customers and market. Each project aim to reduce waste and recovery. Each piece can be made using any aluminum alloy, choosing between material on consignment or own supply.
CONCAVE STARTING HEAD
The concave starting head is a UNIVERSAL or BASIC model, easy to use and getting good results. Excellent as original equipment. Suitable for all types of aluminum alloy.
CONVEX STARTING HEAD
The convex starting head is a MEDIUM or SECOND LEVEL model. Excellent reduction of waste in the cut. Suitable for all types of alloys with dedicated recipes.
“SPAC” SYMMETRIC FLAT BASE STARTING HEAD
The SPAC starting head is a TOP or HIGH LEVEL model. It makes possible to reduce and / or eliminate plaque cut. Excellent for difficult alloys, combined with dedicated recipes.
Service station for maintenance
The service station consists in a number of equipment dedicated to constant maintenance of all technology involved during casting processes.
LUBRICATION UNIT FOR WORKING DESK
The lubrication unit is connected to the casting machine through the PLC which manages the lubrication cycling; it can also be used manuall, entering the data of the lubrication cycle directly on the electrical panel. The system is completed of a pump for transferring the lubricant from the drum. This function allows automatic topping up in case of lack of oil in the lubrication unit.
MAINTENANCE TABLE FOR CASTING TABLE
The maintenance equipment for casting table consists in a steel support structure, where the mould frame is placed for maintenance; an hydraulic cylinder with tilting option and locking sensors and vales; an hydraulic unit Lt 75, powering the system; PLC for tilting and general management.