Molten aluminium dirt and contamination cleaning method | Aluminium Die-casting 

It is a thermocouple to measure the actual temperature of the molten aluminium.

It is available to purchase from furnace makers. Type 'Die casting holding furnace' in Google. There are many furnace makers and you may choose either electric or diesel holding furnace. In this video shown diesel holding furnace. Diesel is more cost effective than electric furnace.

Hi, the flux brand is Pyrotek. You may direct contact to the company. Search in Google as 'Pyrotek Aluminium Flux' then will get their contact details.

We use degasser which is in a tablet form. The tablet is in size of a burger patty. Put one piece inside the molten aluminium and hold it inside to degass.

@@Kannathasan Thank You

Appreciate your long time service in this job. It is one of the hardest and dangerous job. Working in hot environment and there is risk of molten aluminium explosion if water dropped into the furnace. Nearby the furnace is so hot, I couldn't even hold my phone continuously for one minute near the furnace for recording this video. Once complete recorded this video, my phone getting hot and i was required to immediately cooled down my phone with air blower. Really appreciate those doing this job.

Sir aluminum ash price kitna h

He added the flux?

Hi Sir, you may contact Pyrotek to check availability of flux powder for brass. Inside their website mentioned that they do have flux powder for copper, zinc and aluminium. Since brass is an alloy made of copper and zinc, may be Pyrotek have flux powder for brass. I give their website link. www.pyrotek.com/products/foundry/show/Product/powder-fluxes

1 Kg flux untuk 350kg aluminium. Kalau runner campur banyak, kena tambah flux lebih sikit 1.5kg

​@@KannathasanTerima kasih untuk sarannya saudaraku, semoga usaha anda semakin lancar, saya tunggu informasi berikutnya tentang hal ini

Hi, we don't have silver die-casting

Good day Sir. I am from Malaysia. You may contact me by email kanna_747@yahoo.com

Hi, you may contact me via my email kanna_747@yahoo.com

I am not sure about the compound but the brand is PYROTEK

Aluminium flux powder

Water on the spoon is the reason for the explosion. Humidity also will cause explosion. In conclusion, water cannot contact with the molten metal no matter the molten metal is copper, aluminium or magnesium. I heard from my co-worker who worked in die-casting field for about 30 years that, molten magnesium explosion is more greater if contact with water or humidity. Regardless of what metal is it, explosion of molten metal may caused severe injury, burn or even death. So before handling molten metal, must understand safety precautions of what should do and should not do. You can notice some precautions methods in all the die-casting related video in my channel; 1) Raw material bundle on pallet put beside the furnace to pre-heat to remove humidity on ingots. Do not directly take ingots from store then put into the furnace. If there is humidity or water on ingot then it may cause explosion. Sometimes we might missed out to notice humidity or water on ingot during visual checking and it is not possible to check one by one all the ingots for water ot humidity. 2) Since we are not going to put in the whole bundle of ingots into the furnace at once, take some ingots from the bundle then put it on the furnace near the furnace opening. This will be the second layer of safety to fully evaporate water or humidity from the ingots. Temperature near the furnace opening is very high, so any remainings of water or humidity will evaporate at this second stage. Then only put the ingots into the molten metal. 3) If wash the spoon, then make sure to fully dry the spoon before put in into the molten metal. Keep two spoon at least to use another one while drying the cleaned spoon. 4) Make sure the factory or foundry roof above the furnace don't have water leaking. Rain water leaking direct to furnace also will cause explosion. Molten metal explosion is very dangerous and i have saw it myself. Inside the furnace there is cast iron pot with thickness about 2 inch minimum. After the explosion, the pot splits into two pieces and the molten aluminium exploded and spread about 5 meters of radius. So imagine what would happen to human if expose to that type of explosion. So alway follow the safety precautions during handling the molten metals.

@@Kannathasan thank you very much

Hi, mostly iron mixed into molten Aluminium from two sources which is crucible and thermocouple. Crucible made with powdered cast iron compressed to the crucible shape. So the iron powder getting out little by little from crucible then mixed with molten aluminium. Another source of iron is the thermocouple used to detect molten aluminium temperature. Thermocouple made with iron and it is all the while placed inside molten aluminium cause iron from thermocouple mixed with molten aluminium. The purchased Aluminium ingot also need to do Spectrometer test to check actual content. Even though COA or mill cert of the ingot show iron content in spec but it is always better to double confirm the actual iron content by send the ingot sample to third party lab to do Spectrometer test.

@@Kannathasan Thank you very much for the response, really appreciated. I am using graphite crucible and I use aluminium scrap to make ingots. While melting the Fe content is increasing from 0.5 at the beginning to upwards of 1.5 by the end of pouring, which is resulting in not able to make required alloys

You're most welcome. Since you are using graphite crucible, it is not the contributing factor for the higher iron content. Aluminium scrap seems to be the main reason as it is mix of various types of aluminium alloys where some of it may contain higher iron content. One of the types of aluminium scrap called dross in die casting industries, usually contain higher iron content since the molten aluminium exposed to cast iron crucible, thermocouples and plunger. You may try one method. If iron content difficult to bring down, the alternative method would be increase the aluminium content. Instead of using 100% aluminium scrap which contain higher iron content, you may try to add in certain percentage of fresh aluminium ingot to increase aluminium content. As aluminium content increase, iron percentage will be getting lower. Another aspect to take into consideration is, what type device used for check the iron content. Spectrometer test is more accurate. Handheld X-Ray Fluorescence (XRF) test is less accurate. For example, we receive complaint from our customer that Cu% is higher. Maximum Cu% in LM6 is 0.1% but our customer Handheld X-Ray Fluorescence (XRF) test show Cu 0.7% while our spectrometer test done on the sample returned from customer shows 0.3% only. All the while Handheld X-Ray Fluorescence (XRF) test result shows higher reading compare to spectrometer test. If you using Handheld X-Ray Fluorescence (XRF) test for check iron content then consider do spectrometer test for more accurate reading.

@@Kannathasan Thank you for your patience response sir. It was really helpful. If possible can you share your email. Thank you again

@@bhargava7330 You're welcome. Here is my email address. kanna_747@yahoo.com

Ok 👍

Hi sister

Hi, nanga met coke use pannala.

The powder brand is Pyrotek

Pyrotic company ka konsa flux powder use kare

Tin metal ko reffine karne ke liye

Ok 👍

Hi brother, the white powder brand is PYROTEK. You may visit their website for more details. Price details i couldn't get from the company i working as they will not disclose the price. You may directly contact Pyrotek. www.pyrotek.com/products/foundry/show/Product/powder-fluxes

The powder flux brand is Pyrotek. You may get more informations at their website. www.pyrotek.com/products/foundry/show/Product/powder-fluxes

It is called flux powder. Used to clean dirty and contamination from the molten aluminium.

@@Kannathasan gracias amigo

Hi sir, can you explain in details what is the problem with our method? Please share with us if there is better method to improve this process. Your experience and knowledge sharing could benefit to not only me but to other die-castors as well. Any improvements suggestions are welcome.

Why shouldn't it be stirred? Don't you need to start to have everything cling to the flux?

@@TheAngryJean All the while we do stirring after add the flux and so far we didn't facing any problem with the method. So far no complain from our customers on die-casting quality and we do not facing high rejection in die-casting as well. This company successfully running the die-casting process for more than 20 years. Anyhow i am still interested to know why stirring could cause problem since in actual practice we do not facing higher rejection problem because of the stirring.

@@Kannathasan Molten aluminum forms it's own cover flux when the aluminum combines with the atmosphere to form a thin layer of aluminum oxide. When you stir, this layer is being continuously broken which makes gas porosity worse.

@@Kannathasan Molten aluminum forms it's own cover flux when the aluminum combines with the atmosphere to form a thin layer of aluminum oxide. When you stir, this layer is being continuously broken which makes gas porosity worse.

We never do gas blowing. For agitation and deep cleaning of molten aluminium, we using tablet flux. After that use powder flux to clean the dirt and contamination. You may watch the another video in my channel with title 'High Pressure Die-casting' to see how we use tablet flux for deep cleaning.

Hi Sir, noted. Currently we sell aluminium ash to the local scrap shop. Selling price i not sure because it is handling by another department.

www.pyrotek.com/products/foundry/show/Product/powder-fluxes

It is called flux powder.

@@Kannathasan and i guess there is diffent flux powders

Yes there are different flux powders for different types of materials

I am not able to understand your comment. Can you tell in more detail? What is very urgent?

Welcome. The brand name is Pyrotek. You may visit their website for more details www.pyrotek.com/products/foundry/show/Product/powder-fluxes

البوراكس الأبيض

It is one of the important process in aluminium die-casting. Products, such as motorcycle engine covers, are made with the die-casting process. If molten material contains contamination, then it will affect the quality of the part. To remove the dirt and contamination in molten aluminium, powder flux is used.

At Malaysia

Pyrotek flux powder

​@@Kannathasan another name is cover flux 11A

@@arunsundarcreations4146 Thanks for the info sharing brother 👍

It is called flux powder made by Pyrotek