Techniques

We provide various processing techniques meeting professional needs.

・Approximately 20 tons can be melted.

・The heat facility of the foundry is city gas.

・Furnace temperature is 1000℃ and molten metal temperature is about 700℃.

・Molten metal is made in 2 to 5 hours (depending on the amount of base metal).

STEP 1: Melting

The aluminum melting furnace heats and melts solid aluminum raw materials such as ingots and scraps at around 700-800℃. 

 

STEP 2: Casting

2-1 Holding and dosing

Molten metal is processed in a casting machine. The purpose of the molten metal treatment is to adjust the composition (insert the master alloy and check it with a composition analyzer), and degassing (using nitrogen gas and flux). 

 

2-2 Filtering 

Removal of fine oxides and inclusions by filtration tanks and ceramic tube filters. There are 18 tubes made of ceramics.

 

2-3 Casting Machine 

DC casting, vertical semi-continuous casting.

・This is the same casting method used by major manufacturers to create ingots (slabs). 

・There is a 3m pit for making ingots (slabs). 

・Casting (casting) temperature is 700℃. 

・Casting conditions are programmed in advance, and speed, water volume, etc. are automatically controlled. 

TIB wire is blended for refining the casting structure.

STEP 3: Facing machine

A process to remove the segregation layer on the surface. The segregation layer is a non-uniform structure of the ingot (slab) after casting. Grind the upper and lower surfaces for pure aluminum and both surfaces for alloys. To prevent patterns from occurring when anodized. The generated chips are pressed and melted again.

STEP 4: Heating Furnace

The entrance side of the heating furnace has a tunnel shape and exits from the opposite side. Supplying 4 lots per day to hot rolling, 6.5 hours per charge, 24 rods per lot. The purpose of the heating furnace is to make it easier to work during hot rolling and to homogenize the slab structure. As for heat sources, city gas and Akao slabs are treated as inventory, and order lots are from heating furnaces.

STEP 5: Hot Rolling

HOT has a total length of 100m and a rolling mill 50m ahead. Since the line length is not sufficient for thin materials, the material is rolled while being wound up by a winding device. It takes about 15 to 45 minutes to roll one roll. Rolls are automatically polished to avoid coating on the rolls if rolling is continued.

STEP 6: Cold Rolling

Odd number of passes are used to roll to the desired thickness. 

・Roll to 1 to 6 mm. (1-4H is 6mm or more)

・Measured with an X-ray thickness meter, and plate thickness is controlled (control, AGC). Coolant is controlled (AFC) by a device/sensor that automatically keeps the output level constant, and the board is flattened. 

・The rising coil is about 100℃.

Being Coiled

Metal sheets are coiled in order to cool it off to room temperature after hot rolling.

Cold Rolling

A cool sheet passes through cold rolling mills to reduce its thickness from 0.6mm (1/40″) to 5.0mm (1/2″). A metal sheet has shiny and smooth surface and becomes harder.

Slitting

Slit a metal sheet. A plate is cut into designated width from 20mm (3/4″) to 700mm (27 1/2″).

Punching

Punch holes in a metal sheet to gain small pieces of aluminium. Aluminium get cyrindrical shape called slug.

Annealing

Heat aluminium in order to remove residual stresses and adjust the hardness of the metal sheet. Adjusted the hardness and stretch, aluminium sheets become easier to rearrange.

STEP 7: Cold Rolling Mill

The next step is to transform 0.3~1mm rolling, to do that odd number of passes (1,3,5 passes) it makes it smaller than 2-4H, but performance remains the same.

STEP 8: Slitter

 

A strip cutter cuts to the specified width. Burrs are suppressed by adjusting the clearance of the cutter and pressing the plate with a rubber ring. Multi-row. Because the length is different between winding and unwinding (the tension changes slightly), a loop is used to absorb it. Inner diameter φ300, φ500 can be specified.

STEP 9: Press Machine

 

A round plate (disc, circle material) is punched by coil supply. 

・A1 (back) is for processing thick plates, and A2 (front) is for processing small and thin plates. 

・For φ600 or more, use a circle shear.

STEP 10: Leveler Cutting

A line that cuts to a specified length. 

・Sketch size (customized width and length).

(The aluminum standard size is 400 x 1200, and the small plate standard size is 400 x 600).

 

 

STEP 11: Slug Process

 

In the process of cutting to the plate width entering the slitter/press, there are two types of width 150 and 250mm, and the B-SL can cut up to 15mm. 

* Stops in front of the cutter (shows work) and cuts into 2 (3) pieces on the output side.

 

 

 

STEP 12: Slug Process

There are 4 press lines, No. 1 is 125t, No. 2-4 is 200t press. * It would be good if you could explain the product during punching. (Product use) · No. 1 press is 280-300 rpm. ・Show the mold. With the die set method, only the punch and die inside can be recombined.


No. 4 press hole

Drill a hole first, then pull out the circumference. It is structurally automatically sorted in the mold and separated into scrap and products

STEP 13: Slug Annealing

・The No. 6 furnace has a processing capacity of 6 tons (12 cases of 500 kg baskets), and the No. 7 furnace has a processing capacity of 2 tons. 

・Pure aluminum is annealed at 480℃, and alloys are annealed at 400℃ for 8-9 hours. 

・Controlling temperature of aluminum and eliminates odors and variations. 

・Heating with city gas. 

・The adjacent area is the cooling area.

STEP 14: Testing and Packaging

 

Mechanical properties are evaluated by a tensile tester.

The packaging has export specifications for long-term transportation.

 

In addition, there are exterior specifications such as paper wrapping and vinyl wrapping according to requests. And individual packing specification by shrink pack is possible.