Hycal Mk4 applications
Hycal Mk4 is the most versatile solution of the product range. It can be used in any type of aluminium casting operation as shown below:
Low Pressure Die Casting
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
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
Direct Chill Casting
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 .
Gravity Casting
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.
Degassing
Hydrogen control during degassing
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:
- Hycal responds in real-time (within seconds once initial equilibrium has been reached).
- The guided degassing process can be used to program a hydrogen setpoint which will send a signal to the degassing machine telling it when to start / stop.
Continuous Casting
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.