BILLET QUALITY DIFFERENCES BETWEEN CASTER & EXTRUDER

Presented at the International Melt Quality Workshop, Madrid, Spain, 25-26 October 2001 Richard J. Collins R.J. Collins Incorporated E. 8017 Gunning Drive Spokane, WA, 99212 USA Abstract Billet quality to the caster has a different meaning in certain areas than that of the extruder. This paper compares these differences to give insight as to what the billet caster can do to improve his quality to meet the needs of the extruder as well as reduce his own cost of production. The caster must make a profit but also make what the extruder wants or invite competition and possibly lose the extruders business. 1.0 Introduction A Customer Casting Problem Certain aspects of billet quality are different between the billet caster and the extruder. This is best demonstrated during a plant visit to troubleshoot a billet-casting problem. The problem was random occurrences of bleed-outs, horizontal tears and problems casting in air-cast mode. After days of troubleshooting and experimentation, it was determined that the problem was caused by excessive use of chlorine in the degassing box. Large quantities of magnesium chloride were being generated and would stick to the inside of the mold components causing the random defects. When confronted with the evidence the customer made the statement that he doesnt have a metal quality problem because he has not received complaints from his extruding customers. In this case, metal quality for extruding has a totally different meaning than metal quality needed for casting. 2.0 Ideal Billet Quality Defined To better understand the differences between the caster and the extruder, it is necessary to define ideal billet quality. Internally, the billet will have thin shell thickness, small-uniform grains, small dendrite arm spacing, no internal cracks, no inclusions, no pre-solidification, and good homogenization. Externally, the billet will have smooth surfaces, no oxide releases, no surface lapping, no surface drags, no horizontal tears, and no surface or radial cracks 3.0 Billet Quality Depends on the Integrity of the Entire Casting Process Casting quality billet depends on the integrity of the entire casting process and consists of mold tooling, metal quality, water quality, casting equipment, workforce, and optimization of the casting parameters. If one or combinations of any of these areas important to the casting processes are not in control, the integrity of the billet quality can be compromised. Therefore it is imperative that each area of the casting processes be monitored and, as deemed necessary, improved or repaired to alleviate any degradation of the billet quality. 3.1 Mold Tooling All aspects of mold tooling in the casting process are important down to the smallest detail but only two will be discussed as it relates to billet quality. They are the metal feed system of the mold table and the mold design. In the mold table there are two basic types, Hot Top and Conventional Pour. For the mold technology there are also two types, short and long mold bore lengths. Each table and mold design has their pros, cons and tradeoffs some

of which will be discussed in more depth later in this paper as it relates to metal quality. Regardless of table design or mold design, the condition and maintenance of the equipment are of prime importance. 3.2 Metal Quality Casting temperature control, metal cleanliness and chemistry all play key roles in producing good metal quality. Casting temperature control is important by how well and consistent the temperatures are controlled in the furnace and how that affects the temperatures in the trough during start and steady state casting conditions. This has a big impact on how well the casting parameters can be optimized and maintained. Next, metal cleanliness by way of fluxing in the furnace, settling time, and inline trough degassing and filtering are important. This can impact both the internal and external quality of billet quality as shown by the example in the introduction. Finally, chemistry will also affect quality in two important areas. There must be the ability to consistently stay within the control limits of the alloy and each alloy has certain casting characteristics that make it either easy or difficult to cast, i.e. whether the alloy is crack sensitive or has tendencies to stick to the inside components of the mold causing surface defects. 3.3 Water Quality The casting process is affected by the water quality, specifically, water temperature, filtration and chemistry control. Water temperature plays an important roll in quenching the billet. For instance the difference between the Leidenfrost heat transfer temperature coefficients of 5oC water compared to 50oC is as much as 45% difference.(1) The results of this difference may require some plants to have a summer and winter casting practice for best casting results. Water filtration is typically the biggest process problem of all. In many mold table designs, water distribution inside the table is based on the size of the water orifices feeding each mold. The principle is the smaller the baffle hole, the bigger the pressure drop, the better the water distribution. However, the smaller baffle holes are more prone to plugging and casting defects. Also, many water systems are designed for return water filtration only or there are only strainers in line that are not effective at filtering some types of debris such as algae deposits. Finally, the heart of the whole water quality issue is water chemistry control. There is a delicate relationship between keeping the right balance of ph and additives which will determine how well the water quenches the billet, prevents biological growth of algae, and mineral water deposits in certain parts of the mold which can cause casting defects. 3.4 Casting Equipment The important aspects of the casting equipment are quality, reliability, design, function, layout, level of process automation and good maintenance programs for each. This includes all equipment associated with casting such as furnaces, degassing and filtering equipment, trough layout, casting pit, and even includes homogenization equipment. 3.5 Workforce The level of job experience, amount of training received and individual motivation and job satisfaction are equally important in relation to the workforce and must be continually considered and supported to be successful. The level of operator job experience is important but if there is not a training program to support all levels of experience, problems occur. If an operator is not given the correct training, procedures and tools tailored for his plant and his equipment, he may be good at doing some of the wrong things. This is especially true for short mold casting technology where success is in the details in doing the little things correctly. Lastly, it is important that there be job satisfaction and individual motivation as a person can have experience and training but if not motivated, the process will suffer to some degree. 3.6 Optimized Parameters Optimizing parameters for the individual conditions of each plant are imperative if quality billet at low cost is to be achieved. One example is intermittent cracking. In too many instances, when this occurs, the immediate response is to slow down the cast speed. This is treating the symptom instead of finding the cure. Also, there are always trade-offs for too hot or too cold casting parameters. Problems from cold casting conditions are not as

obvious as they are for cracking and hot casting conditions. Therefore, the start and run parameters of speed, water flow and metal temperature must all be optimized for the individual conditions of each plant to achieve the very best results. 4.0 Extruder & Caster Billet Quality Differences Now that billet quality and casting process are defined, the differences between extruder and caster billet quality can be discussed. For the purposes of this paper the following areas will be addressed: alloy chemistry, thin shell, inclusions, internal cracks, homogenization and surface defects. 4.1 Correct Alloy Chemistry Correct alloy chemistry is dependent on the quality of the following casting processes. Raw materials (metal quality related), furnace quality design and maintenance (casting equipment and manpower), alloying and fluxing procedures (casting equipment and manpower) and good in line metal treatment (casting equipment). While both the extruder and caster want correct chemistry, the extruder wants a narrow alloy range for key extrusion dies and profiles to maximize extrusion speeds and minimize extrusion defects. The extruder typically needs billet from multiple suppliers with the downside being different billet qualities. In many cases the poorest quality billet limits the extrusion practices. In contrast, the caster wants to be able to cast with a wide alloy range. This allows sending the same product to multiple customers and thus keeping inventory and production costs low. Billet casters struggle to keep alloys within specified limits whether they are wide or narrow, with of course more problems involved with the narrow alloy ranges. 4.2 Thin Shell A thin shell maximizes the extruders productivity by minimizing the size of the butt discard without butt end defects. This reduces the amount of scrap and butts that need to be recycled resulting in cost savings. It also means that more saleable extrusions can be obtained using the very same metal units. Thin shell is also most important when anodizing extrusions to minimize streaking. The extruder wants a thin shell and the emptying Figure 1: Emptying diagram shows importance of thin shell diagram shown in Figure 1 (2) demonstrates the reason why. An emptying diagram shows which part of the billet will flow into the profile at different stages of the extrusion by using a different marker material implanted in the billet at five different locations. The top half of the diagram shows the marker shell thickness of a short mold of 1.2 mm deep. The bottom half of Mold the diagram shows the marker shell thickness for a long mold of 10 mm deep. Note, the 10 mm shell thickness can move into the profile when only 22% is extruded compared to 80-90% for the 1.2 mm. Also, the difference in total area of a 178 mm billet between a shell thickness of 1.2 mm compared to 10 mm is 39.9%. Liquid To achieve thin shell, the caster must use short mold casting technology. Refer to Figure 2 and 3 to compare the differences between short and long mold sump profiles to explain why. Note, in long mold casting as shown in Figure 2 there are two modes of solidifying the billet. Approximately 10% of the heat is extracted through the mold wall and then there is a delay before the second mode of direct water, quenches the billet. During this delay,

Water

Solid

Figure 2. Sump profile for long molds.

alloying elements last to solidify can migrate to the surface creating a rough billet surface, then there is an enriched zone, and then a depleted zone that all adds up to as much as 10 to 15 mm deep.(3) Mold In the short mold casting as shown in Figure 3, there is only one mode of solidifying the billet, which is by direct water impingement. Liquid In this mode, solidifying the billet eliminates the alloys migrating so (3) that there is less than 1 mm shell thickness. This gives very smooth billet surfaces, more uniform alloy distribution, smaller more uniform grain size and finer dendrite arm spacing. These qualities can contribute to a reduction in extrusion breakout pressure, improve extrusion speeds and properties, and reduce surface defects. The Water Solid downside of short mold casting is that it is more sensitive to problems and changes in the casting process discussed above. This requires better overall process control, and process automation is recommended to have as much control over the casting process as Figure 3. Sump profile for short molds. possible. 4.3 Inclusions The extruder wants no inclusions because internal inclusions and oxide films increase extrusions surface defects, die wear, die maintenance and reduced extrusion speeds. Low inclusion and oxides require the caster to maintain good metal quality but also may require a change in casting technology. There are two major ways the metal is delivered to a mold table. They are conventional pour and hot top technologies. In the conventional pour technology, Figure 4, the metal enters a trough and is delivered to a mold through a downspout and float that controls the level of metal in that mold. There are many downsides to this technology one of which is high flow turbulence that cause oxide and inclusions to be generated and released into the billet. Another problem is the warping of the distribution pan makes it difficult to maintain the same metal level in each mold for consistent billet surface quality. In hot top technology, Figure 4, molten metal from the furnace all the way to the mold table under pours beneath a layer of oxide skin. The molten metal is not exposed to the atmosphere and the metal flow rates are very low so that oxide and inclusions are not generated like it does in the float and downspout system. To prevent inclusions, the caster needs to use hot top technology. 4.4 Internal Cracks
Figure 4.Conventional Pour Technology & Hot Top Technology

Both the extruder and the caster want crack free billet. Cracking is dependant on 1) optimized casting parameters, 2) adapting to changes in the casting process such as water temperature changes, 3) operator performance that is not controlled by automation such as hold time before cast start, and 4) proper preventative and crisis maintenance of molds and other casting equipment.. 4.5 Billet Homogenization The extruder wants properly homogenized billet. To achieve this, the caster must have state of the art homogenization equipment. This equipment must have good furnace temperature control; good internal temperature distribution so that all billets achieve equal temperatures, and proper cool down rate and/or quench. 4.6 Surface Defects

The extruder wants defect free surfaces free of oxide skins or patches, vertical drags, horizontal tears and surface cracks. Always try to determine if the defects are mold related, table position related or occurs randomly. If the defects occur randomly then the caster needs to look at better control of his casting process. This means: 1. Troubleshoot mold and casting pit equipment problems, 2. Train and motivate operators making sure they do the little important things correctly, 3. Optimize or adjust casting parameters to changing plant conditions, 4. Upgrade to new technologies when needed, 5. Implement a preventative maintenance program for casting equipment and mold tooling, 6. Obtain periodic technology consulting to conduct casting audits and keep current with latest findings and developments. This will also provide valuable information as to how you compare to other casting competitors. 5.0 Conclusion In conclusion and in all cases, the caster must supply the extruder with the billet quality needed. He also needs to provide quality in his casting process in order to produce it. 6.0 References (1) (2) A. Larouche, Y. Caron, K. Kocaefe Impact of water extraction and casting conditions on ingot thermal response during D.C. casting Light Metals 1998, pp.1059 to 1064. Oddvin Reiso, Vidar Jonsen. Flow of the Billet Surface in Aluminum Extrusion, Light Metals 1992, pp. 503-517. T. A. Johansson, C. Johnsson. Comparative extrusion test with Wagstaff MaxiCast AirSlip billets and Float Cast DC billets of alloy AA6063 Granges Technology Centre, Internal Technical Report

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