Raw materials, scrap and alloy elements with input quality control are charged into the melting furnaces by a Charging Car (Tomorrow Technology -Italy). The perecentage of raw metarial and scrap is controlled very carefully,
The charged materials are checked when the furnace reaches the melting temperature. The amount of dross is observed and refining and slag making is carried out with the flux feeder before removing the dross again with a Tomorrow technology charging car or a suitable machine. The resulting slag is separated from physically bonded liquid aluminum with suitable vessels in the Slag Press manufactured by Tomorrow Technology.
After the degassing process with Flux Feeder, a chemical analysis sample is taken for the addition of pre-alloy elements. According to the spectral analysis results, pre-alloying elements are added to the molten aluminum. After ensuring that the analysis of the liquid metal is homogeneously distributed with the magnetic stirrer (EMS) manufactured by ABB, a chemical analysis sample is taken again. The result is guaranteed to meet the targeted alloy values.
Liquid metal transfer from tilting type melting furnaces to the casting machine is done through specially prepared runners. To provide homogeneous heat, the transport runners are equipped with electrical resistance heaters.
The most important part of the Metal Transfer System is the part we call degasser. In addition to the degassing process we carry out in the melting furnace, the final degassing process is carried out with the Alpure degasser we purchased from Novelis (Italy). The gas rate provided here is measured and monitored with a vacuum test device.
The liquid metal coming out of the degasser is filtered with ceramic foam filters (CFF) and then prepared for metal casting.
Billet casting process is carried out by Wagstaff Casting machine. After the ingots with diameters of 127 - 152 – 178- 203 mm and length of 7000 mm are produced with our 2 casting tables and 4 mold sets in our facility, their physical appearance is visually checked. Their internal structures are checked with an ultrasounic device to ensure that there are no internal cavities.
The produced billets were removed from the casting pit with the Billet Tong purchased from Almatech company and placed on the cutting machine's bench.
The lengths of the poured extrusion billets are cut according to the order specifications and prepared for the homogeneous process. Internal structure features are prepared for final quality control by means of 3 batch type homogeneous furnaces in our company. After homogenization, the samples taken for microstructure are examined in the laboratory and reported. Extrusion billets are prepared appropriately in the packaging area and shipped to the customer.