Aluminum extrusion on-line quenching is a challenging and key technology for the production of industrial aluminum profiles. The aluminum quenching system designed by us here at Save solves the problem of poor flatness tolerance, poor dimension tolerance, coarse grain and low strength of the industrial aluminum profiles in the production process. The aluminium quenching system achieves a balanced cooling of the materials.
|Properties of quenching system on procedure||Quenching system on procedure comparison|
|Others advanced quenching system on procedure||"SAVE" quenching system on procedure|
|Cooling mode||Air cooling, high spray pressure cooling||Strong air cooling, air-mist mixed cooling, mist cooling, high spray pressure cooling|
|Cooling speed and area||Enough cooling area and cooling treatment combined air cooling, high spray pressure cooling to manage the cooling speed and strength based on section difference. But the cooling intensity can't be controlled from weak to strength, so it always causes cooling blank in procedure.||Enough cooling area and cooling treatment combined air cooling, air-mist cooling, mist cooling, high spray pressure cooling to manage the cooling speed and strength based on section difference, and each cooling mode could control from weak to strength freely and to match the various requirement for section shape, and without any cooling blank in procedure.|
|Adjusting function||It could manage the strength and directivity, but the design can't get the treatment of segmentation in longitudinal direction so as to cause the bigger different properties in one profile.||It could manage the strength and directivity, and the design can get the treatment of segmentation in longitudinal direction, and each segmentation could manage the cooling speed so as to ensure mostly the same properties and less the deformation in one profile. Lowest fault in machinery.|
|Controling system||Man-machine interface, high automation to easy operation highly maneuverable. It is designed the function of memory, the recording can be saved and repeated on next production.||All directives and process parameters can be achieved through the man-machine interface. There are strong function of memory, the recording can be saved and repeated on next production. The productivity and efficiency are improved rapidly, also it is less waste and energy-saving. Lowest fault in machinery|
|Quality||Most of the mechanical properties are stable and dimensional precision isn't high; a little deformation, productivity||The mechanical properties are very stable and high dimensional precision; lowest deformation, higher productivity; environmental protection, energy saving and cost saving.|
The aluminum quenching system can be used for cooling complex industrial aluminum profiles without dead angles. They improve the ordinary cooling devices in the straightness of aluminum profile, rate of finished product, and the uniformity of cooling and size accuracy. The aluminum quenching system is widely used for complex cross sections and wide aluminum profiles where the materials of products are mostly hard processed and low yielded, such as auto parts, mobile phone shells, and laptops. During the production of complex profiles and special alloy profiles, we recommend the use of our quenching system on procedure, which ensures a high yield, production efficiency, improved economic benefits and a great reputation among customers.
1. Four cooling modes: Air cooling, air-mist combined cooling, mist cooling, high pressure spray.
2. To manage the cooling strength based on the section difference, to avoid deformation as less as possible.
3. With a higher intensity than air-cooling, air-mist mixed cooling effectively reduces energy consumption.
1. This quenching method meets cooling strengths of different metals, ensuring all mechanical properties are met.
2. Reduce the deformation to ensure product size accuracy.
3. Pass rate of the products is improved. : excellent quenching treatment avoids bending, deformation, substandard hardness, non-uniform hardness and other poor mechanical property situations, so that the pass rate of profile extrusion is greatly improved.
4. Energy-saving, reduced production costs and easy and intelligent operation.
5. Differential adjustment of multi- channel nozzle water flow
6. The water flow of each channel can be adjusted according to the actual needs, ensuring uniform cooling of the extruded profiles, thus reducing deformation.
1. Air-Mist Cooling
According to the diversity of profiles, our original creation of an air-mist cooling method achieves differential adjustment on both sides, and the upper and lower surfaces of the profiles. This cooling method avoids product deformation caused by uneven cooling. The application of this cooling method has achieved very good results in actual production and it is popular among our customers.
2. Subsection Water Cooling
An original patented design, subsection water cooling achieves uniform cooling of the front and rear sections of the profile. Subsection water cooling plays a very important role in controlling the deformation of industrial profiles.
3. Subsection Lengthened Air-Cooling
In working with the large cross-section and thick aluminum profiles, the extended air cooling adds an air cooling process after water cooling, mist cooling, and common air cooling. The lengthened air-cooling process ensures the cooling effect in high speed extrusion, and reduces deformation. The subsection lengthened air cooling process is widely used for large tonnage machines.
4. Adjustable Cooling Method
An adjustable cooling cover is applicable to different cooling methods. Unlike the traditional fixed cooling mode, the cooling methods can be adjusted freely according to the characteristics of the profile. The adjustability of the cooling modes ensures more efficient and targeted cooling of profiles, thus achieving ideal cooling effect.
5. Intelligent Control
Water-cooling, air-cooling and mechanical operation all adopt PLC control. The PLC control system not only promotes simple and convenient operation of the equipment, but also helps to achieve the desired technological index. Equipped with a touch screen for operation control and adjustment of the technological parameters, the machine has parameter memory of the control system to save the proper quenching process for each profile. When producing the same profile for the second time, parameters are directly transferred to the machine and the machine automatically carries out the quenching process, effectively improving the efficiency of adjustment.
Case Study: Tablet PC Shell Quenching
Usually made of 6063 T6 aluminum sheet, the thickness of tablet computer shell is usually thicker and requires a higher flatness tolerance.
With a slow cooling speed, air cooling of the material results in a poor quenching effect, coarse grains and low mechanical property. With a fast cooling speed, a flood cooling tank or water spraying results in uneven cooling area, product severe deformation and poor flatness tolerance.
The best solution is a combination of cooling methods to achieve effective cooling. Air-mist cooling is used for the initial 4-5 meters of the products to decrease the product temperature to about 250°C. Ensuring uniform cooling of the product, the following 1-2m is sprayed by water to reduce the product temperature to about 100°C. If a section of the product (4 meters is better) is treated with air cooling, the cooling effect is better. After the cooling process, the products achieve the required cooling strength and give full play to the mechanical properties of the alloy. With less deformation and appropriate flat tolerance, the products avoid water stains, dark spots and other defects. It is a very important procedure but often ignored. A final quenched tablet computer shell is shown below.
aluminum quenching system, heat treating furnace, aluminum extrusion cooling, quench hardening