Purpose: Melts aluminum ingots or scrap into molten aluminum for casting.
Type:
Induction Furnace: Uses electromagnetic induction for efficient, uniform melting. Capacity: 500–2000 kg, suitable for medium-scale production.
Gas-Fired Reverberatory Furnace: Common in larger operations, with capacities up to 50 tons.
Specifications:
Temperature: 660–750°C (melting point of aluminum is 660°C).
Power: 150–500 kW for induction furnaces.
Relevance: Ensures a consistent molten aluminum supply for casting 7-inch round bars.
2. Casting Equipment (Hot-Top Casting System)
Purpose: Casts molten aluminum into round bar shapes (e.g., 7-inch diameter).
Components (as used in Foshan, e.g., by Nanhai Boqiang Machinery):
Casting Platform:
Upper Platform: Steel structure with refractory lining, includes a distribution launder to guide molten aluminum.
Crystallizer (Mold): Forms the 7-inch diameter bar; made of copper or graphite for high thermal conductivity and durability.
Dummy Bar (Ingot Puller): Supports and pulls the solidifying aluminum bar downward.
Cooling System: Enclosed water chamber with cooling water (flow rate: 50–100 L/min) to solidify the aluminum bar rapidly, minimizing defects like porosity.
Accessories: Graphite rings, transition plates, and distribution launders ensure uniform aluminum flow.
Specifications:
Mold Diameter: 177.8 mm (7 inches).
Casting Speed: 50–150 mm/min, adjustable based on alloy and diameter.
Output: Can produce 10–50 bars per cast, depending on platform size.
Relevance: Hot-top casting, as offered by companies in Foshan, is ideal for producing high-quality 7-inch aluminum round bars with minimal internal defects.
3. Extrusion Press (Alternative Forming Method)
Purpose: Forms aluminum round bars by extruding heated billets through a die, often used for smaller diameters or when casting isn’t preferred.
Components:
Billet Heater: Heats aluminum billets to 450–500°C.
Extrusion Press: 1000–2500 ton capacity, forces the billet through a 7-inch round die.
Run-Out Table: Cools and straightens the extruded bar.
Specifications:
Extrusion Ratio: 10:1 to 40:1, depending on die design.
Speed: 5–20 m/min.
Relevance: Extrusion is widely used for 6061-T6 aluminum round bars (as noted in prior market data), offering tight tolerances and smooth surfaces. However, for 7-inch bars, casting is more common due to size constraints in extrusion.
4. Cutting and Finishing Equipment
Purpose: Cuts the cast or extruded bars to desired lengths (e.g., 2.6 m to match your steel pipe lengths) and improves surface quality.
Components:
Circular Saw: Cuts bars to length with precision (±1 mm tolerance).
Surface Treatment:
Brushing Machine: Removes surface oxides or defects.
Anodizing Line (Optional): Adds a 10–25 µm oxide layer for corrosion resistance, critical for humid environments like Ecuador (70–90% humidity in Guayaquil).
Specifications:
Saw Blade: Carbide-tipped, 500–800 mm diameter.
Anodizing Tank: 5–10 m long, uses sulfuric acid electrolyte.
Relevance: Ensures the 7-inch aluminum round bars meet your length and surface quality requirements for export or equipment manufacturing.
5. Quality Control Equipment
Purpose: Ensures the round bars meet mechanical and dimensional standards.
Components:
Ultrasonic Tester: Detects internal defects like porosity or inclusions.
Hardness Tester: Measures Brinell hardness (e.g., 95 HB for 6061-T6).
Relevance: Critical for ensuring the bars’ tensile strength (310 MPa for 6061-T6) and suitability for your applications (e.g., machining into equipment parts).
6. Auxiliary Equipment
Degassing Unit: Removes hydrogen gas from molten aluminum to reduce porosity in the final bar.
Filtration System: Uses ceramic foam filters to remove impurities, improving bar quality.
Cooling Water System: Recirculates water (200–500 L/min) to maintain mold temperature during casting.
Environmental and Operational Considerations
Corrosion Resistance: Equipment should have protective coatings (e.g., epoxy or galvanized) for durability in humid environments like Ecuador.
Power Supply: 380V/50Hz, 3-phase, common in China; adjustable to 120/240V, 60Hz for Ecuador.
Safety Features: Emergency stops, protective guards, and temperature sensors to prevent overheating.
Practical Implications for Your Use Case
Application: The 7-inch aluminum round bars can be used to machine components for your steel strapping production line (e.g., rollers for the straightening machine or supports for the uncoiler/pallet mover [Previous Artifacts]).
Export: The equipment ensures high-quality bars for export to Ecuador or Algeria, suitable for humid conditions when anodized.
Integration: Can be paired with your existing production setup in Tianjin, enhancing your ability to produce or utilize aluminum components alongside steel strapping and pipes.
If you need detailed schematics, a supplier comparison, or integration plans, I can assist further!
