Aluminum

Aluminum is the most abundant metal on earth, whose properties such as low density, conductivity, corrosion resistance, and high recyclability make it a distinguished material in the industry.

Its highly complex processes, controlled by strict quality standards, result in products with high added value. Then, minimizing losses and optimizing processes is essential to maximize profitability.

The processes where this material is used for manufacturing are casting, forging, heat treatments and welding. In this sense, they require effective thermographic monitoring, for which the bcbMonitor 4.0, together with FLIR equipment, are the appropriate solution for such activities.

Applications

The process of high-pressure die casting or HPDC for its acronym consists of injecting liquid aluminum, or some alloy, at high pressure and speed into the mold, which opens after completing its cycle time and the desired piece is obtained.

Some of the advantages of HPDC are superior uniformity, lightweight parts, good mechanical properties, very good finishing of the surface, and thin-walled components. To achieve these characteristics is necessary to have a correct temperature control throughout the process. To achieve these characteristics is necessary to have a correct temperature control throughout the process.

bcbDieScan is our solution for continuous and uninterrupted temperature monitoring throughout this process, for example, in the following applications

  • Continuous temperature inspection in molds
  • Spray control.
  • Temperature validation of Liquid metal
  • Robot-assisted thermal inspection.
  • Temperature control of part outlet.

The gravity die casting or GDC for its acronym consists of pouring liquid aluminum, or some alloy, from a ladle to the casting molds. This type of foundry is characterized by long cycles and the ability to produce complex parts, as sand cores can easily be inserted.

Gravity die casting is useful to provide certain properties to the products, such as strength and rigidity. When working with liquid metal, it is crucial to check its temperature, as well as the temperature of the molds before pouring the aluminum.

Thanks to the bcbDieScan, control software developed by bcb together with automated FLIR cameras, a close inspection is possible in this process, facilitating the reduction of scrap and the increase of quality in applications such as

  • Validation of Filling temperature.
  • Checking sand molds.
  • Continuous monitoring of molds.
  • Inspection for demoulding of parts.
  • Painting and preparation of molds.
  • Parts inspection for coring.

Low pressure die casting or LPDC for its acronym consists of injecting liquid aluminum, or some alloy, slowly from a pressurized furnace until it reaches the mold.

This process has advantages over the final product such as lower porosity, good density and resistance, high production and excellent metallurgical quality in the manufactured parts.

One of the biggest challenges is controlling the casting temperature and the correct preparation of the molds. For this, tools such as our bcbDieScan software and thermography are integrated to optimize and improve quality in the following applications:

  • Inspection of mold heating for start-up
  • Thermal assistance to the operator for mold cooling.
  • Continuous inspection of molds.
  • Painting and preparation of molds.

Aluminum extrusion is a process where the material is molded at 480 ~ 550 ° C by passing it through a die of a certain width. The dimension of the vent will be the same dimension that the final product will have, which is known as the transverse profile.

Temperature plays a very important role in this process, as it gives the aluminum the desired characteristics, such as hardness and finish. For this reason, it is very important to monitor the temperature of the material prior to entering the die as well as the friction temperature when it passes through the mold.

The bcbDieScan allows us to continuously monitor the temperature of this process, by locating, autonomously and unattended, thermal imbalances, generating alarms at different times of applications such as:

  • Continuous monitoring of casting temperatures.
  • Checking the temperature of the billet at the exit of the furnace.
  • Inspection of castings in the cooling zone (quench).

Gallery

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