Hycal 100 offers most of the measurement capabilities of the Hycal 1000 i.e.:
However, it does not include the following:
As such, several of the functions available in the Hycal Mk4 and Hycal 1000 are not available in the Hycal 100.
It is particularly suited to a multi-furnace operation where a multiplexed hydrogen control network is required – such as a low-pressure die casting foundry environment.
A Low Pressure Die Casting (LPDC) furnace has the additional complexity of being a sealed environment so that air pressure can be applied to force the aluminium up the riser tube into the mould above.
Hycal is unique in its ability to measure permanently in this environment by sealing to a custom flange plate with a compression fitting.
High Pressure Die Casting (HPDC) is generally thought not to suffer the same level of issues with hydrogen porosity compared to other castings methods. However, it remains necessary to control the hydrogen level as it can still have an influence of the mechanical properties such as tensile strength.
Hycal is unique in its ability to measure permanently in real-time within the degassing furnace, transfer ladle and also at the holding well at the HPDC furnace
Hycal Probe Actuator located above the trough immediately prior to the casting table allows full automation and enables the entire cast to be monitored for dissolved hydrogen .
Measuring hydrogen content in the process of gravity casting aluminum is paramount to ensuring the quality and integrity of the final product. Hydrogen, when present in excessive amounts, can lead to severe defects like porosity and gas-related defects in castings.
These defects compromise the structural integrity, mechanical properties, and overall performance of the aluminum component, potentially leading to catastrophic failures in critical applications. By accurately measuring and controlling the hydrogen content throughout the casting process, manufacturers can mitigate these risks, enhance the material’s properties, and produce high-quality aluminum castings that meet stringent industry standards.
This precision not only ensures the safety and reliability of the final product but also plays a pivotal role in reducing waste and optimizing production efficiency, making hydrogen content measurement an indispensable aspect of gravity casting aluminum.
Typically, the hydrogen content of the aluminium would be measured during or just after the degassing treatment or at the holding furnace immediately prior to casting. However, due to the speed at which Hycal is able to reach equilibrium, it is also uniquely possible for Hycal to measure the hydrogen content directly within the mould itself, thereby providing a dissolved hydrogen measurement for an individual casting.
The graph below shows a ‘gassing-up’ process followed by degassing treatment, verified finally by a static measurement.
The ability to control hydrogen content in the aluminium is unique to Hycal for the following reasons:
The measurement and control of hydrogen during continuous casting operations such as wire production is a critical part of the process.
Hydrogen related defects may compromise the structural integrity, mechanical properties, and electrical properties, potentially leading to catastrophic failures in critical applications. By accurately measuring and controlling the hydrogen content throughout the casting process, manufacturers can mitigate these risks, enhance the material’s properties, and produce high-quality aluminum castings that meet stringent industry standards.